The new fuel tank is on and I now have a 600+ mile range. The new tank has a Facet fuel pump feeding through a water trap, a micron filter, 3 non-drip line splitters, a one-way valve, an 8mm to 6mm reducer and finally a 6mm T piece to the balance pipe on the bike's tank. When the bike's tank runs dry I just flick the switch and fill it upfrom the sidecar tank. It takes about 15 mins so I can replenish whilst looking for somewhere to pull over! Simples!
I've also put an Odyssey Extreme Racing 45AH battery in a container under the rear box. I've put a die-cast alloy box on the side of the 'sit upon' box which has all the electrics in. Split charging relay, fuse box, 2 waterproof latching cigarette lighter sockets and 3 switches. One for the fuel pump, one to break the circuit of the split charging relay and one to kill the sockets. The reason to cut the circuit is that the winch - a Champion Mighty Atom - will draw too much power for the relay to charge the battery at the same time so I need to kill the circuit. I've also put an isolator in the battery cicuit so I can boost the bike's battery when/if needed.
All the wiring and nearly all the fuel lines are encased in convoluted conduiting.
I've also fitted a waterproof connection on the sidecar headlight wiring.
