okay, i know i have seen larger fuel tanks for samurais, but my dad has a tracker '92 i believe and is tired of having to fill up so often and would make for much annoyance on long camping trips, so my question is are there larger fuel tanks made for the tracker, or a larger tank from something else that will fit? we are hoping to keep the tank in the stock location, but all input is welcome, thanks

Have to custom make one.

the fuel tanks on the 4 door trackers/sidekicks  have a larger tank

-Lance

the fuel tanks on the 4 door trackers/sidekicks  have a larger tank

that is good to know. does anyone know if it will fit in a two door? and also, how many more gallons are we talking about?

Have to custom make one.

hmmm.... would rather have something simple, but understand that is not always the case. so if i did have to make one, (i havent been under the tracker in a while) how much room is there to work with down there?

thanks for the help so far guys

I didn't know the 4-door had more capacity. When mine is pretty darn empty (according to dash), I take 12ish gallons. I thought I remembered reading in my manual that's max capacity (per Suzuki), but... it's been a while, and my memory isn't what it used to be. I can't tell you how much more room you have to go. I'm planing on either spending some $$$ and cutting up a custom aluminum box (for weight), or just getting some steel, and welding my own. Most people doing this on other rigs seem to squeeze out an additional 10-40% depending on the rig, and how crafty they are. That means 13.2 to 16.8 for me.


Actually... come to think of it, I'm doing a 2-door build next time, so... maybe not that big. Will keep a pulse on this thread to learn more...

I've been thinking about this issue for  quite awhile now myself.  There isn't much room for expanding the tank size on a 2 door, unless you want to go the body lift route. A 2 " body lift would allow you to expand the tank upwards and increase the volume. ( I instead raised my tank for better ground clearence.)  I've thought about this, you can buy a brand new Trackick fuel tank off ebay for less than $100. Section it, add another 2.5 " to the middle, and increase the volume that way. The problem with the Trackick tanks is they are pretty well trapped between the frame rails front to back, and side to side, so about the only way to expand is up or down. I'd like to hear some ideas too, aside from carrying a jerry can, which I do.

Quote

the fuel tanks on the 4 door trackers/sidekicks  have a larger tank

that is good to know. does anyone know if it will fit in a two door? and also, how many more gallons are we talking about?

It won't fit. The tank is designed to fit between the wider rear frame rails on the LWB.

thanks rhino. i was hoping it would swap easily, but you just bursted my bubble.  lol at least i wont waste time, effort and money on that now.

bentparts, i think your solution would probably be the simplest way to go rather than fab up a whole new tank. how thick are gas tanks? and is it safe to weld on them with the fumes from the gas? (fuel, check. oxygen, check. heat, check.) according to my checklist, we do have a good recipe for creating a fire, or considering it is a tank, possible explosion?

and on a second note, has anyone installed the larger gas tanks on a sammi? that is my ride, and want to know the pros and cons.

thanks everyone for all the help so far.

You can weld on tanks. Wash the hell out of it with a good detergent. Then trickle fill the tank with a constant feed of non-explosive gas (like Co2) while welding. This will remove oxygen from the equation.

I was considering a whole-new-tank instead of expanding the original is 'cause I can still expand it a little bit side-to side (maybe?), and construct it out of thicker "self armored" steel (and not need a skid plate). Problem with my design ideas is I've got 2 4-doors, and never seen the tank in a 2 door (which is going to be my next build). I didn't even know there was a frame width difference 'till this thread  If it's similar, the pinch weld is about 1/2" on each side, and there's another 1/2 or so between the pinch weld, and the frame (and front to back). It doesn't seem like much, but every little bit adds up when you're doing a custom tank. I'd have to look, but I might be able to get brave, cut a hole in the 'floor' and expand up into the rig somewhere too.

Maybe another super-crazy idea... but Buell's (motorcycle) actually have fuel in the frame (keeps COG lower)  Maybe that will spark some outside the box thinking...

that would be a neat idea, and would keep cog low, but as much abuse as the frame sees, and as many things that are attached to it, i don't know how well it would work, but it would give you ALOT of room for gas. especially if you used the frame and a standard fuel tank.  how much do you guys know about propane conversion, and is it worth it?

I'd think the best way to utilize the frame would be to treat it as a 2nd (reserve) tank, so it's isolated in case the frame fails  This could open up a can of worms if the frame cracks on-trail, and you need to do some welding on it to get home... not everyone carries enough soap, running water, c02 or whatever you'd need to make the frame safe to weld on again. Then again - how often do Suzuki frames crack 

Propane is really a whole other discussion, but I'll hit the highlights... Tank location is probably the biggest hurdle. "Is it worth it" depends on what you've got, and what you plan on doing. On Samurai's they make a HUGE difference (all the bennies of going FI, and ditching the restrictive stock carb). They're also the most difficult to locate a tank in (cargo space is limited). It's my understanding LP is out of the question for tin tops & 4-doors, because tanks need to be in well-ventilated areas.

I think the early sidekicks, like mine were equiped with a 10.2 gallon
tank, but the later trackers had like a 12 gallon tank, the 4 door tank is
about 14 gallons if I remember right, and no it don't fit the 2 door, I looked
into that as a 14 vs 10 gallon tank is like 40% increase in capacity

Wild

I'd think the best way to utilize the frame would be to treat it as a 2nd (reserve) tank, so it's isolated in case the frame fails   This could open up a can of worms if the frame cracks on-trail, and you need to do some welding on it to get home... not everyone carries enough soap, running water, c02 or whatever you'd need to make the frame safe to weld on again. Then again - how often do Suzuki frames crack 

alright, so if someone were to go this route, what would be the first thing to accomplish. pressure test the frame? put an air fitting in the frame, and fill it with some air would probably be easiest i would think. also, would you need to coat the inside of the frame rails with something to keep it from rusting? i have been thinking about this quite a bit, and it actually sounds very feasible

I'm by no means an engineer, but here's some of my best educated guesses...

Pressure testing sounds like a good way to make sure it's "water tight". I'm not sure coating the inside of the frame would be necessary, but not a bad idea either (I'd only bother if I were doing a frame-off anyway). Fuel doesn't rust metal, and the inside was designed (probably via thickness?) to handle normal condensation flash-style rust anyway.

I was thinking about this some too. The biggies worry I'd have is in a collision. The frame could easily fail in a high-speed crash, and spill fuel... wherever & make a hazardous situation in a hurry  :'(

   was thinking about this some too. The biggies worry I'd have is in a collision. The frame could easily fail in a high-speed crash, and spill fuel... wherever & make a hazardous situation in a hurry 

(having too much fun with the quote button) hmmm.... well, i know on helicopters the have a fuel tank that is basically made up of rubber.... like a big water balloon, so if the tank is punctured, it is basically self sealing ( the same way you can stick a skewer through a balloon through the top and bottom, without it popping) though i do not think the event of cracking my frame is something that is something to worry about, it wouldnt hurt to have some kind of fuel bag(?) that would go inside the frame to limit leaks... i dont know. but it would definitly be something interesting to try.  my next question is assuming it passes the pressure test, what would be the next step, atteching large filler type hose from the frame to the tank? a Y or T on the existing filler hose to the tank, possibly with a check valve? and also would you need a pump to move fuel from the frame to the tank, or will gravity do the work, or will the regular fuel pump create enough suction to pull that fuel in the frame through? still think this is a very cool idea, and very do-able

keep the ideas flowing