jimcorliss
New member
DIY Auxiliary fuel tank, and some other mods
Attached are photos of 8 gallon fuel tank I instaled in my 95 V Max 500 DX,
It self fills the main tank... (It will run dry and I still have a full main tank after 55 miles) Here are some specifics for anyone wanting to add an extra tank.
A 1/4" fuel line feeds fuel into the snowmobiles gas tank air vent hose. As the snowmobile uses fuel a vacume is created which draws fuel from the auxiliary tank. Beneath the auxiliarys fuel fill cap is a 3/16" air vent hole drilled which becomes the vent for both tanks. A shuttoff at the tank is needed as the auxiiary might overflow the main tanks cap when opened.
Pex tubing was run through the base of the seat for the fuel line to pass through without pinching. Taking a 1/4" steel rod in an electric drill was enough to drill a channel through the seats foam so the pex tubing would pass.
The fuel cap I had was not self venting and the tank was difficult to fill so adding an elbow with a plug serves as a vent. I remove the plug before filling the tank. A wing nut was welded to the plug to make it easier to remove.
The unexpected benefit was a more comfortable ride for the passenger of this 2-up sled. I removed the trunk and found that there was only a small amount of seat foam between the passenger and the trunk which was felt in the spine when bottomming out. I used closed cell urethane foam from a stearns life preserver to fill the gap where the trunk sat. I was also able to press a rectangle of this foam under the riders seat which helps as well. (this same foam is also sold as a seat warmer to sit on while hunting, etc).
The trunk was moved aft behind the tank after trimming off the bulge which sat under the passengers seat. The vinyl velcro door was replaced with plastic cut from the bottom of a 5 gallon bucket. Bolted on and wing nut to use as latch. The trimmed off bulge was covered with flat piece of plastic bolted in place.
1/8 and 3/16" iron strapping and bolts hold the tank secure and it was placed onto a flat washing machine lid to serve as a base.
Also can bee seen is a pair of drop down brackets from 1/8" stainless plate which drops the track 2 3/4".
Also added a wider footrest for the passenger.
I had previously extended my bumper with some angle iron with holes drilled which I used to bungie a plastic rubbermade tote for fuel... this extension made a shelf which the trunk attached to. The taillight wires were lengthend.
My Vmax DX gets only 7mpg with 2 heavy adults and supplies and this tank is needed to go along with my children and grandchildren with newer 4-stroke and lighter sleds.
Pleased with all these mods.
God bless,
Jim
Attached are photos of 8 gallon fuel tank I instaled in my 95 V Max 500 DX,
It self fills the main tank... (It will run dry and I still have a full main tank after 55 miles) Here are some specifics for anyone wanting to add an extra tank.
A 1/4" fuel line feeds fuel into the snowmobiles gas tank air vent hose. As the snowmobile uses fuel a vacume is created which draws fuel from the auxiliary tank. Beneath the auxiliarys fuel fill cap is a 3/16" air vent hole drilled which becomes the vent for both tanks. A shuttoff at the tank is needed as the auxiiary might overflow the main tanks cap when opened.
Pex tubing was run through the base of the seat for the fuel line to pass through without pinching. Taking a 1/4" steel rod in an electric drill was enough to drill a channel through the seats foam so the pex tubing would pass.
The fuel cap I had was not self venting and the tank was difficult to fill so adding an elbow with a plug serves as a vent. I remove the plug before filling the tank. A wing nut was welded to the plug to make it easier to remove.
The unexpected benefit was a more comfortable ride for the passenger of this 2-up sled. I removed the trunk and found that there was only a small amount of seat foam between the passenger and the trunk which was felt in the spine when bottomming out. I used closed cell urethane foam from a stearns life preserver to fill the gap where the trunk sat. I was also able to press a rectangle of this foam under the riders seat which helps as well. (this same foam is also sold as a seat warmer to sit on while hunting, etc).
The trunk was moved aft behind the tank after trimming off the bulge which sat under the passengers seat. The vinyl velcro door was replaced with plastic cut from the bottom of a 5 gallon bucket. Bolted on and wing nut to use as latch. The trimmed off bulge was covered with flat piece of plastic bolted in place.
1/8 and 3/16" iron strapping and bolts hold the tank secure and it was placed onto a flat washing machine lid to serve as a base.
Also can bee seen is a pair of drop down brackets from 1/8" stainless plate which drops the track 2 3/4".
Also added a wider footrest for the passenger.
I had previously extended my bumper with some angle iron with holes drilled which I used to bungie a plastic rubbermade tote for fuel... this extension made a shelf which the trunk attached to. The taillight wires were lengthend.
My Vmax DX gets only 7mpg with 2 heavy adults and supplies and this tank is needed to go along with my children and grandchildren with newer 4-stroke and lighter sleds.
Pleased with all these mods.
God bless,
Jim
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jimcorliss
New member
DIY- Repairing a torn seat and stitching the vinyl...
OBTW... The seat vinyl from the trunk was stitched tight around my new foam backed seat with ice fishing line and then sealed with aquaseal+cotol hardner. (used to repair wetsuits, etc).
This is an excellent way to repair a torn seat which I did also. Grundens also sells a repair sealant for their outdoor gear which I haven't tried but I was told costs less.
OBTW... The seat vinyl from the trunk was stitched tight around my new foam backed seat with ice fishing line and then sealed with aquaseal+cotol hardner. (used to repair wetsuits, etc).
This is an excellent way to repair a torn seat which I did also. Grundens also sells a repair sealant for their outdoor gear which I haven't tried but I was told costs less.