After installing a RTR High Clearance Cat-Back Exhaust on my 2023 2-door Bronco Badlands I noticed a new voided space where the original muffler was. It got me thinking about how an auxiliary fuel tank might be able to be installed in that space to supplement the dismal 16.8-gallon original fuel tank. I soon found out that there were no products presently on the market. After months of designing and R&D, this past week I finally installed a 9+ gallon aluminum passthrough fuel cell and skid plate. The fuel cell was constructed by a local commercial welding company out of 3/16“aluminum with AN fittings for hose connections. The skid plate was constructed by a fabricator friend, using a cardboard template that I provided, out of 1/4“steel plate which was powder coated. The fuel cell is vented to the original filler pipe keeping the EVAP system functional and rollover safe. The skid plate not only protects the fuel cell, it also increases the integrity of the rear portion of the chassis. Besides the numerous hours of R&D, I’ve spent close to 6K for production and supplies. I am very satisfied with the results. At 17 MPH the range of my Bronco is now about 460 miles compared to the original 285-mile range. You can see by the accompanying photos that the fuel cell is tucked up above the rear bumper and improves the departure angle compared to having the original muffler. My fabricator friend and I are discussing making this design available commercially at possibly a lower price point. Stay tuned!
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