Mike, that sounds downright disappointing.    

Sorry you are having issues with your new tank and your framework.      



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Today my shipment of 3 cheap Chinese "T" fittings finally arrived from the Christmas Container Sargasso Sea Black Hole Entanglement of SLOWNESS and I can start making final progress on my auxiliary tank plumbing on my Savage.

All I had to do was cut into the rubber fuel line and put the "T" in and connect to the auxiliary gas tank and valve in the back.    Not more than an hours worth of fiddle work even counting making a trip to the gas station for some gas to top it all up.

I filled up the main tank and then let it back flush through the new system to see where equilibrium was between the two tanks.   Back tank goes completely full when main tank drops down 3-4 inches from a full condition.  

Use method can be simple, fill both tanks up, turn the main one on and run that one until about half empty then turn the back one on too and then let the "total gas left" equilibrium show visibly in the clear tank on the back.    The two tanks join just below the main tank level then go through the large pleated paper fuel filter and then the line drops to go down to the carburetor.

When you run both tanks dry, you still got a standard reserve in the main tank.

Yes, if I get totally stupid I can make a mess with gas flowing on to the ground.   I can do this by asking a full main tank to backfill downhill to the smaller back tank.*

Rather than guessing, it would be easier to just run the main tank for about 60-80 miles then turn them both on and just look to see what you got left.

Because of the self-balancing equilibrium you always have 2x the gas showing in the back tank, plus about a 15-20 mile reserve amount in the main tank.





*If I fitted a 2.6 gallon jug similar to what I use in the Barcalounger it would not overflow as the top of the taller jug would be more equal to the top of the main tank.    Total capacity would be right at 5 gallons.   It would all be "top heavy weight" though ..... not really good for mountain handling.

ALSO NOTE THE DOUBLE WRAP OF MILK JUG PLASTIC "PROTECTION" AS THE FUEL LINE RUBS UP AGAINST A SHARP EDGED PIECE OF AIR SYSTEM CLAMP.

..... and when you come out from the saddle bag strap you do this with a cheap plastic shut off valve ....


What is neat is there is no high spot in this system that builds up an air lock as the back and forth between the tanks keeps the main line flushed free of any air build up.  

Trash in the tanks is trapped and held by the large pleated paper fuel filter, which keeps that 'ol debble    "dirty carburetor problems"    at bay.

Keep us posted on how easy the swap is!

I've seen the 2.5 gal tanks made for luggage racks , but my rack is already busy with a trunk.

Feller,

I often thought that if I ever take a long trip again I would go for an axillary tank mounted behind the drivers seat and set it up so it would be a snap to take it off after returning home.

I like the idea of a separate tank like you are showing rather than a huge main tank the may be uncomfortable for riding 8 hours at a time.

Kenny G  

Mike, I totaled up just over 22k last year. But I must admit a couple thousand was on my old PC800. A long weekend trip to Richmond and back ALL INTERSTATE was just more suited to that than the Thumper.
On the bright side of that trip was meeting a bunch of family at my aunt's 99th birthday party. I had to show my cousin on his trike to my other cousin's house, and he said he couldn't follow a Honda, I said "That's OK Bob, I'll drive slow!"
He bought that Harley new in 11', put the trike kit on it in 13', when I saw him in Sept. he had 93k on it!! Now that he is retired he just won't stay home! He's been to the 4 corners of the country, the 4 corners, and summer of 15' he went from Buffalo to Alaska and back! And hates Interstates, just wants to ride on 2 lane roads whenever he can.
Now I like 2 lanes, BUT, sometimes I want to get there quick. I am mulling the Pikes Peak Hillclimb this year. 26 or 27 hundred miles each way in May needs a little advance planning.

Well , the low-ball offer worked !  

Sometimes it does ...  

So $32.59 + SH.  for an extra .6 gal (30 miles on my bike and habits) , and the dash moves up to the triple tree .  

O-yea : I get to paint to suit myself.