Super Jet DIY internal fuel fill

[motozachl]

In under 20 minutes and for under $20 you can too have an internal fuel fill setup! This quick mod uses just a couple basic tools and plumbing supplies:
1.5" cap (4094702)
2" no hub coupling (45392)
1.5" x 1.25 hx jam adapter (42690)
2x 1/4" 90* barb elbows (81387)
3ft fuel lines
rod
scrap plastic lid
zip ties
drill/bit
marker
tin snips

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First we'll start with the easy part, cap the stock fill tube using the 1.5 cap.

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Next take apart the coupling and trace the seal onto a piece of plastic and cut it out, I used a thick lid to a plastic container. This will become the cap in which the new pickups will go through

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Drill two holes (make sure not to drill them too large) in the cap and push the barb elbows through making sure they are snug. I was going to jb weld them in but I found that this was not needed

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Next up is the new pick up tubes. First take a long rod or pvc and set it in the tank marking it where the top of the cap will sit. This will make sure that the fuel lines will stay at the bottom of the tank and not flop or bend around when in the tank. Now cut and zip tie the fuel lines to this rod and to finish the cap/pickup simply push the fuel lines onto the barb fittings

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Finally put the 2" straight coupler on the top of the fuel tank along with the new cap/pickup

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Congradulations now your done! You can now hold more fuel for thoes long rides!

 

[SeXI]

haha awesome!!!

 

[ratboy120206]

nice, but even easier way.. take stock fuel neck and cut a whole to size in the tank screw it in and and leave stock fuel selector as is

 

[Mark44]

Easier yet.... Unscrew factory cap on nose of ski and fill up ski with fuel screw cap back on.

Mark44

 

[WFO Speedracer]

Or you can use the Shonuff method for internal fuel fill, he sends me a tank without internal fill, I send him one with internal fill both people now happy !

 

[BruceSki]

I can hold more fuel in my tank by filling it with the ski tilted and using the extra area in the stock fill tube to hold more fuel than a capped off internal fill.


Plus I don't end up with a ton of fuel inside the engine bay.


Nice DIY method though.

 

[WFO Speedracer]

Easier yet.... Unscrew factory cap on nose of ski and fill up ski with fuel screw cap back on.

Mark44

My next build will have external fuel fill

 

[FearMyWrX]

Easier yet.... Unscrew factory cap on nose of ski and fill up ski with fuel screw cap back on.

Mark44

Internal fuel fill for me is just seems like wasted time and money. Not to mention every time you want to fill up you have to pull your hood.... No thanks.

I guess the only reason you'd have to pull your hood is so you can show off your gay spray-painted protec pipe... Lol @ Rick

 

[Joker]

I figured out if you just put foam in the tank you are able to maximize more space than doing a gay internal fill.

But nice write up I will probably use part of this.