Not discounting the idea, but unless you see yourself wayyyy off-highway or trying to IBA stuff there's just not much value in going with the Aux. Fuel Cell.

Even out here in the big West fuel is available every 150 miles or so. 

BUT, if you wanted to do it I'd send a PM to Justin or post up in the Iron Butt forum.  Lots of experience to draw from.

Regardless, let's answer the question.  The first thing is to source a tank and figure out how to strap it down to the bike/rack/rear seat.  Second thing is to figure out some way to transfer fuel to the pump.  This could be a gravity feed into the main gas tank or it could be a separate fuel pump.  Third thing is to plumb the lines. 

It's not hard but for me I just didn't want to have something permanent on a bike.  Rather, I've gone the route of MSR bottle or other gas cans for my needs. 

Here's one option to consider. 

http://tourtank.com/3gallon.html

Also remember:  each gallon is worth 8# or so plus the weight of the tank.  So, a 3 gal tank is going to be a 30# option…held up high on a bike. 

I put a Kolpin Fuel Pack on my '06 Wee for my Alaska trip and called it good.

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I have the 5 gallon tourtank (looks like a keg). I didn't get the iron butt version though. When I took my first ride into Canada, I discovered that gas stations are _not_ 150 miles apart and almost (as in jerking the Harley to get gas over the hump) didn't make it to the next gas station. I actually ran out as I crossed over the highway and coasted to the pumps hoping they took a credit card.

Since then I've had to use the extra gas a couple of times on the 'busa, both on the trip to Alaska.

Carl

All my bikes have an aux fuel cell, since I do LD rallies and iron butt rides. If you decide to do it and want to do it fairly cheap, go with a tourtank. First off, remember, you will need to get the fuel into your main tank. That will require putting in a bung fitting. You can either use one that seals with O-rings, or weld one in. Here's a good write up for installing an O-ring sealed bulkhead fitting: http://www.fjr1300.info/howto/bulkhead.html. That's for an FJR, but the concept is the same. I personally prefer a welded in bung, because I never want to think about it again. Anyway, here's some pics from my last aux cell install on the FJR.

My friend who is handy and has a nice shop with a welder helped me make a mount for the fuel cell. This replaces the back seat. Uses two bolts in the front and slides into the groove that used to hold the back seat.

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For the tank, my friend again helped me weld in a bung. To do that, I pulled the tank off and removed the filter and pump assembly. I cleaned the tank with soapy water, then left it full with water and drilled the hole for my bung fitting while it was still full of water. Protip: No matter how clean you think you got a gas tank it can still blow up in your face. That's why I left it full with water . If you can place something under the hole, like a cup or something, do that to catch the filings. I put some loose duct tape on the inside of mine to catch the big stuff, then cleaned the rest with an oily rag taped to a magnetic wand - or just an oily rag by hand if you can fit your arm in.

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Now that the tank is drilled and ready for the fitting, I brought it over to my friends shop to weld in the fitting. Again, I repeat, no matter how clean you think it is, gas fumes are evil. You need to displace the gas vapors inside with something when working on a tank. In this case, we used the exhaust from my car.

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Here's the final result:

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Once the bung was in the tank, and the bracket was done, it was just a matter of plumbing with gas hose from the aux tank to the main tank. I have a shut off valve and quick disconnect along the way, and I'd recommend those to anyone adding a tank.

If you need valves, bulkhead fittings or quick disconnects, Mike Langford sells them from his web store: http://maplefarkles.com/index.php/products/94-plumbing-items. If you just want the whole thing done for you, he can do that as well; custom tank and all.

Anyway - if you decide to proceed with this and need any help/have questions, feel free to shoot me a message. I've done three bikes so far, and have done a lot of research on the topic. Happy to help an .Orgier

Hey Justin... Why did you choose a bung on the tank vs going with a T-fitting in the tank's fuel delivery (do you have in-tank fuel pump)?

Thx. Mine was carb'd with gravity feed to low pressure fuel pump so I could easily "t" into the tank's output line.

My first question would be "why do you need that kind of range?"  The Wee has a decent range to begin with.  I've never been overly concerned with running out of gas on the Wee.  On the C14 (about 100 miles less range) I have been very concerned a few times but it just means a little planning ahead and maybe a fill-up when you're at half a tank just because you know you need a full tank to get to the next gas.


The other thing I would suggest is when you're not on your "home turf" never assume you can buy gas with a credit card.  I always have cash for just such an occasion.  Cash that's either hidden in you wallet for years on end or on the bike/gear somewhere.

My first question would be "why do you need that kind of range?"  The Wee has a decent range to begin with.  I've never been overly concerned with running out of gas on the Wee.  On the C14 (about 100 miles less range) I have been very concerned a few times but it just means a little planning ahead and maybe a fill-up when you're at half a tank just because you know you need a full tank to get to the next gas.


The other thing I would suggest is when you're not on your "home turf" never assume you can buy gas with a credit card.  I always have cash for just such an occasion.  Cash that's either hidden in you wallet for years on end or on the bike/gear somewhere.

Need is a relative term.  I have an 84 mile commute each way.  That puts me getting gas every day.  So, it's really just a matter of lazy and having the option of going 2 whole days without having to get gas. 
And, it could get worse before it gets better on the whole mileage thing.  Also, since said commute is 81 and 70, I'll be consuming gas at a pretty healthy rate so I don't want to be flirting w/ the top of the range on the bike if I have a really spirited ride one day.

Well lazy makes sense.    Just hook up a trailer with a 55 gallon drum to tote behind.

I wouldn't worry too much about the highway mileage.  The wee hums along at highway speeds and above with relative ease in regards to fuel consumption. 

I've got nothing to add other than having an actual keg of BEER on your bike would be really awesome.   

   way more fun than gas

Look down once in a while?  It has a blinky indicator.

Look down once in a while?  It has a blinky indicator.

True, but it isn't bright enough to catch the eye.  And when I am riding I tend to be looking forward and scanning the streets for hazards.

I've got nothing to add other than having an actual keg of BEER on your bike would be really awesome.   

 

He doesn't look at the dash.  Speedometer be damned!   

My mind keeps coming back to "trailer" with a "nice sized" tank. Not too large (heavy for start/stop when it's full) but large enough to perhaps make it 3 to 4 days??? A week would be sweet but perhaps too heavy. One of those 1-wheel or narrow trailers.

Trailer disconnected and the bike is back to "normal".

Love the tank Clay.

The funny thing is I had about as much range with the stock tank on my Wee.

I'd love to add a gallon of so to the C14 though.  Now you've got me thinking.

Sweet! You're a mechanical genius Clay!