Performance

Remember that movie "Mad Max," where a fresh-faced Mel Gibson had to fight for every last drop of fuel? Well, don't expect that scenario to happen anytime soon, despite dire predictions about dwindling reserves of crude. There's still a lot of oil in the ground, but the cost of mining those reserves will continue to rise, along with prices at the pump.

Diesel Upside
You can reduce fuel expenses in a number of ways. In Europe, where fuel prices are twice as high, if not more, fuel-efficient diesels are much more popular, comprising 50 to 80 percent of the vehicles on the road. (Note that diesel has 17 percent more energy per pound than gasoline, so mileage rates are much higher with diesel engines.) Considering that only three percent of consumer vehicles run on diesel fuel here in the U.S., it's easy to see why many auto manufacturers predict a double-digit growth in the stateside demand for oil burners.


If you're part of the small minority that already drives a diesel, there are several good reasons for increasing the fuel capacity of your pickup. With a larger tank either in or under the bed, you can shop around for the best price on fuel, and load up for a really long haul. (In fact, you can extend your range so much that you'll probably need to stop for human fuel a few times before your truck needs replenishing.) Having extra capacity is also a plus when towing increases your rate of fuel consumption.

Underbody Upside
The advantage of an underbody tank is that it doesn't take up any precious space in the cargo bed, as is the case with an auxiliary tank. The latter also may require extra plumbing and valves for switching between two tanks.


As one example, Aero Enterprises makes replacement tanks for every domestic make of truck, and also tanks for toy haulers, RVs, and all sorts of custom applications. Instead of plastic (used by vehicle manufacturers), Aero fabricates its underbody tanks from enamel-coated, aluminized steel with internal baffles, a drain plug and through-bolted steel mounting tabs. (Plastic tanks are typically secured with metal bands that can rust or trap debris that chafes against the outer surface. Also, plastic tends to swell with changes in temperature, which can lead to leaks around the fuel pickup.)

Continued on Page 2

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Photo Guide

Note the Aero tank's strong steel mounting tabs that are through-bolted to the vehicle frame.

A custom-fabricated recess was added to clear the gear splitter.

All the necessary hardware and hoses are included with the Aero tank.

Old and new, plastic versus steel tank. Which one would you rather have in your truck?

The sending unit on the fuel pickup assembly on older Dodges is known for wearing out as soon as 40,000 miles or so. Aero replaced it with a newer type made of a more durable material.

The factory fuel-pickup assembly is transferred to the new housing that's included with the Aero tank. All of the fittings on the old assembly are removed.

Before attaching the new mounting plate, it has to be measured for the right height. Even so, the tank gauge will read full for the first 15 to 20 gallons, since this OE part is not modified for the bigger tank.

With the mounting plate secured, the factory fittings can be re-attached.

Carefully insert the fuel pickup assembly into the Aero tank.

The plate needs to be seated properly in the top of the tank.

Two-part epoxy adhesive is used to seal the top the tank.

Use a floor jack to raise the tank in place. Then attach the filler-neck hose to the Aero tank fitting.

Drill bolt holes in the mounting flanges, and through-bolt the tank to the frame rails. No thin straps to rust or snap here!

Here's what can happen to factory straps for plastic tanks: They either rust out or trap debris that rubs against the tank.

With 60 gallons in reserve, we're ready for 1000 or more miles of non-stop cruising!



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