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A Suggestion:
When you re-assemble the piping, point the stem of the valve straight up. In the position it is in now, the force's of opening and closing the valve are tightening and loosening the fitting.
If you point the valve straight up, then all the fuel won't be able to drain from the aux tank.
If you point the valve straight up, then all the fuel won't be able to drain from the aux tank.
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Leave the valve in the horizontal position, just like it is. When you tighten the valve allow the "stem" of the valve to point up. All the fuel will drain.
I'm assuming those are tapered pipe threads? If so, and it's still moving by hand, you should be able to go another 3/4-1 turn without any issues.
If you can't get the handle to go around to where you want it without it still feeling too tight, get a pipe tap for the elbow and tap it deeper slightly, like 1/4-1/2 turn, then install the shutoff and repeat until it tightens where you want it. Just go slow, maybe even start with 1/8 turn.
The valve adds leverage, so you need to get that fitting in as tight as you can. The downside is that when you reach a certain point, the risk of it snapping gets pretty high and you wont know it until it happens. Get some never seize and use that on the threads. It will prevent galling which is what causes most fittings to snap. Make sure though that it doesn't go past the first threads, you don't want it mixing with the diesel. If any gets on the tank side of the fitting, wash it off and try again.
Lots of good advice here. Unfortunately, there's still 20+ gallons in the tank. I wonder if the vacuum trick would work for this but for now I don't have a lot of time to work on it so I can wait for the tank level to go down. I'll report back if I work on it again.
I am able to turn the valve by holding it in place with my index finger and lifting the lever with my thumb. I would probably do it that way even if all was tight.
I had to retape a fitting on my aux tank. The tech guy at Titan Fuel Tank told me to use Blue Monster teflon tape. It is a bit thicker than regular teflon tape and it is rated for diesel. You should be able to get it at Home Depot or Lowe's. I picked up a roll at my local ACE Hardware store.