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Yup...... I've noticed it's been a year and a half since I've updated this thread, but things have been progressing at retirement speed. Also, I've been saving this little update for when I managed to get it finished, and knew that I hadn't blown up the truck or burned it to the ground. The whole thing started after I had converted the truck to fuel injection (FiTech for those that ask). I realized there wasn't really a point in keeping dual fuel tanks, as it would necessitate dual dedicated high pressure fuel systems, and they'd have to be routed through a marine grade crossover valve. That just seemed like a lot of unecessary plumbing, when I could just get the large rear tank (35 gal), and eliminate the front fuel tank. So, I did just that, and I've recently installed a custom length tube style fuel sending unit, which is compatible with the new Dakota Digital RTX gauges I installed.
The weirdness began when I started to wonder what the heck I was going to do about a fuel tank door that didn't go anywhere anymore. That sort of thing bugs me.......and yes, I know they have medication for that nowadays. The catalyst occurred when one day I was walking by the truck, and I had left an extension cord hanging in the hole of the fuel door, and I had the beginnings of an idea..........not a GOOD idea, but I saw the potential for some silliness. So, I began with laying under the truck, measuring repeatedly, making lots of drawings, and driving myself a bit nuts.
What was the idea, you ask? Well, I decided, to install a 3000W inverter where the front gas tank used to be, and routed it up through conduit to the gas door, to a weatherproof plug for 110V at the gas door. The largest hurdle was designing the weatherproof but ventilated enclosure so that the inverter would be relatively safe. Once I got the plans figured out, I made a 3d mockup with foam board, and took it and my plans to a metal fab shop to make it out of stainless steel (easy to clean, won't rust). Once I got the box, I drilled it for the cable glands, as well as the vents (they have a good flow, but difficult to get water into with an internal switchback design). I also found a way to utilize the old gas filler tube, and the weatherproof plug fit it perfectly. I ran conduit from the plug through the filler tube, and then down to the box for a weatherproof route. I then ran '0' guage wire from the secondary battery to the inverter, through the frame, all the way back (it was the shortest route). That way, the inverter can run when the truck isn't running, but is supplemented by the alternator when it is running. Finally, I wired an interrupt switch into the original fuel tank selector switch, so when you turn it to the front tank, it activates the inverter (I like to hide my modifications as best I can).
I managed to test it out last week, and to my surprise, I didn't melt the truck down. Everything works just as it should. Anyway, I know I don't post as much as I used to, but at least I have been busy........and busy with a modification that I've never seen anyone else do before (I do like to try new stuff from time to time). Photos are below.......... enjoy.
