My WVO system for the 24V (Waste Veggie Oil)

**patracy** · 07-13-2008, 04:37 PM

Just documenting my WVO setup I've constructed for my 1999 Cummins 24V with the VP44. I should state that I'm not going to run this as a 100% WVO setup. I'll be running a percentage of diesel fuel or Kerosene in the tank with the WVO as well to help reduce the coking effect WVO can have. In any case I've constructed my system with K.I.S.S. in mind. Not so much in overall complexity. But in components.

I'll start with the tank first. It's a plastic marine tank. It's 23 gallons. It fit inside my toolbox. I wanted to be able to have everything hidden out of sight. Best of all, it was only $33. I did have to clean a layer of varnish out of it (lacquer thinner works great!) and I had to replace the sending unit. I picked up a sender from the local marina shop. $33 for it.

I used a Mallory 4060FI fuel pump for the WVO setup. You can get away with a typical vane style pump for diesel. But WVO is to viscus for a vane pump. The oil will cause the vanes to "stick" in place and stop pumping. The Mallory fuel pumps are a gearotor style pump. So they use a gear to pump.

I used a series of fittings to step it up to 1" NPT into a goldenrod filter. The goldenrod filter is nice since it's clear. I can check on the filter media. One of the worries with WVO is polymerization. A traditional screw on cannister filter wouldn't allow you to see this in that event. Next I stepped it down to a tee with a adjustable pressure regulator. This bleeds off excess pressure back to the tank.

From that point the output from the pump/filter/regulator/tank is fed into my hose in hose setup.

The hose in hose is a 1" ID hose with 1/2" aluminum fuel line inside. I drilled out the center of the 1/2" compression fittings to seal them off. There are tees at both ends to allow coolant to pass through. This allows heat transfer. The key to WVO setups. The total length of the hose in hose is about 15ft. So the fuel is heated plenty by the time it reaches the engine. Here's the end that meets the engine.

I fastened the hose in hose along the frame rail. Also I used a 5/8" heater hose for the return.

I tapped off the head for the heat supply. I used a ball valves to adjust flow. It's also a good idea to valve off the coolant flow in and out in the event you have a leak.

The return line is tied back into the heater core return.

Here's a pic of everything plumbed as well.

On to the engine itself. I used a pair of 1/2" check valves. Most people use expensive valves. But in my opinion that's a more expensive means to do so. And leads to failures.

I used a 4 way fitting to allow for a port for my fuel pressure gauge and my warning light as well.

While I was working on all of this I upgraded my diesel fuel system as well. I used 1/2" fuel lines with a 1/2" draw straw. I used AN fittings I picked up from summit racing. I used the 12mmx1.5 to -8AN adapters. And 90def -8AN fittings.

The VP44

The new fuel pump for diesel

Now for the return. Since the dodge is a return system. You have to have a selector valve for the return.

Now about the return valve. Since I've got a dual pump setup with check valves. You have to have a delay to keep the selector valve feeding back to the WVO tank for purging. Otherwise you'll pump the WVO from the IP, injectors, and lines back into your diesel tank. I built a timer based off the 555 chip. Crude looking inside, I know, but it works.

Here's a video of the controller in action cycling through sources and a purge cycle.
YouTube - WVO controller with purge cycle

Since I don't smoke I used the ash tray for a holder for the controller. Also notice the fuel gauge.

All said and done I've got about $500 in my setup. So in about 5 tanks it'll be paid for.

Hope this helps.

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

Last edited by patracy : 07-13-2008 at 04:57 PM.

**patracy** · 07-13-2008, 04:40 PM

If anyone is interested I can tell you a little more about the wiring. There's quite a bit of wiring to all of this.

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

Joe Reitman · 07-13-2008, 08:47 PM

Very detailed write up. I hope it works great.

Too much work for me though...

Where did you find the 23 gallon tank for $33?

Thanks.

__________________
John 3:16, John 14:6. Silver 6/06 Mega Cab Dually, G56, 2wd, 3.73, Gooseneck, Iggee seat covers, Tekonsha Controller, Opti Lube Summer Blend, Mopar Tailgate Spoiler, Rokktech
'03 KX250/310, '01 KX500

**patracy** · 07-13-2008, 08:51 PM

Quote:

Originally Posted by Joe Reitman

Very detailed write up. I hope it works great.

Too much work for me though...

Where did you find the 23 gallon tank for $33?

Thanks.

Detailed? Nahh, you should read my technical writings for work. This was just the cliffnotes.

I've got a good bit of time in the setup. As well as work. But it'll be worth it.

I picked the tank up off ebay. They had two listed. The other was sniped on me.

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

**patracy** · 07-13-2008, 08:53 PM

I'm certain someone will ask. The black pipe for the heater will be getting a brace. I've got it already cut and drilled. But I just moved and haven't ran my 220V outlet for my welder yet. (I've been asked this on the other forums I've posted this on)

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

Challenger · 07-14-2008, 03:41 AM

Looks like a system that will work.I wonder if the wvo would pass through the filter easier after it is heated,how long until the first test run?

__________________
96 Dodge CTD 3500 4x4 black extracab dually auto 3.54 no mods 1980 Mack Cruise-Liner Cummins N14 370/430 hp 10spd,air ride

**patracy** · 07-14-2008, 05:28 AM

Quote:

Originally Posted by Challenger

Looks like a system that will work.I wonder if the wvo would pass through the filter easier after it is heated,how long until the first test run?

During the summer I'm not going to worry with the temp of the oil in the tank. I've left enough slack on my coolant return from the hose in hose in the toolbox to plumb in a loop for coolant if needed to the tank. However after running it on diesel yesterday I noticed that the fuel is heating in the tank since the fuel system is a return system. I need to borrow the infrared thermometer to get some real numbers on the temp at each point.

I've got to suck down another couple of gallons of fuel from the tank. I used some two stroke oil in it to differentiate the fuels while inspecting the return selector valve for purging. I'm just a little cautious about mixing diesel, WVO, and oil. I don't think I'd have an issue with it. But I know Diesel + WVO + WEO = clogged filters.

I want to install my brace for the coolant line as well. And I need to replace one leaky fitting at the check valves. Then I'll be ready for a go.

I'm surprised I didn't get any grief for not using food approved containers and plumbing for my setup from you.

(Kidding!)

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

speed185187 · 07-14-2008, 06:21 AM

nice setup, I'm working on an 86 gallon aux fuel tank from an old truck tool box. Still in the prep stages. Also picked up 120 gallons of WMO that's actually really clean. I get it from the navy auto shop here in norfolk. Really clean stuff.

I have to finish sanding the tank and install pipes, bolt it to the bed, set up my filtration setup. Gravity drain from a 55 gal drum through 20micron - 10 - 1. With magnetic filters on all three.

Aux tank will have a valve between the aux tank and truck filler with a flow meter. Open drain for aux tank to fill normal tank with varying amounts of WMO when i fill up. I'm going to start off with a 50/50 mix and see how it runs, than go up from there.

__________________
00 2500 2wd ext cab, SB. (BHAF, silencer ring MIA, Boost, EGT, FP Gauges, Breather bottle relocate, Fass 150/150, Fireball 150's, VA smart box, 4" exhaust)
03 Jetta TDI 5 spd "See tdiclub.com for all mods"

**patracy** · 07-14-2008, 06:28 AM

Quote:

Originally Posted by speed185187

nice setup, I'm working on an 86 gallon aux fuel tank from an old truck tool box. Still in the prep stages. Also picked up 120 gallons of WMO that's actually really clean. I get it from the navy auto shop here in norfolk. Really clean stuff.

I have to finish sanding the tank and install pipes, bolt it to the bed, set up my filtration setup. Gravity drain from a 55 gal drum through 20micron - 10 - 1. With magnetic filters on all three.

Aux tank will have a valve between the aux tank and truck filler with a flow meter. Open drain for aux tank to fill normal tank with varying amounts of WMO when i fill up. I'm going to start off with a 50/50 mix and see how it runs, than go up from there.

Sounds interesting. I'd personally look into replacing the lift pump with a gearotor style pump though. Also how do you intend on monitoring fuel/oil ratios? Doesn't sound like it can be all that precise?

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

speed185187 · 07-14-2008, 06:36 AM

I also bought a walbro pump for a pusher pump setup. Will be wired up with a relay off of the stock lift pump.

Fuel/oil ratio is going to be measured when i drain the wmo from the aux tank to normal tank with something like this
Tuthill Digital Flow Meter — 1in., Model# 820 | Control Valves, Meters + Nozzles | Northern Tool + Equipment

__________________
00 2500 2wd ext cab, SB. (BHAF, silencer ring MIA, Boost, EGT, FP Gauges, Breather bottle relocate, Fass 150/150, Fireball 150's, VA smart box, 4" exhaust)
03 Jetta TDI 5 spd "See tdiclub.com for all mods"

**patracy** · 07-14-2008, 06:46 AM

Quote:

Originally Posted by speed185187

I also bought a walbro pump for a pusher pump setup. Will be wired up with a relay off of the stock lift pump.

Fuel/oil ratio is going to be measured when i drain the wmo from the aux tank to normal tank with something like this
Tuthill Digital Flow Meter — 1in., Model# 820 | Control Valves, Meters + Nozzles | Northern Tool + Equipment

Gotcha! That sounds like it'll work nicely.

__________________
1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan.
Parts to come: 150hp sticks, turbo, and bigger exhaust.

speed185187 · 07-14-2008, 06:54 AM

I'll be working on the tank some more this afternoon when i get off work. I can snap some pictures then of the parts laying around. When I get everything set up, the truck should be getting the equivalent of 45mpg on D2. Depending on how much WMO i'm running. I'm also building a Biodiesel processer for my VW TDI. I've got a steady supply of 40gallons/week for WVO to process for that. My car will go well over 700 miles on 15 gallons so i'll have some left over for the dodge to drink.

__________________
00 2500 2wd ext cab, SB. (BHAF, silencer ring MIA, Boost, EGT, FP Gauges, Breather bottle relocate, Fass 150/150, Fireball 150's, VA smart box, 4" exhaust)
03 Jetta TDI 5 spd "See tdiclub.com for all mods"

07-13-2008, 04:37 PM	#1 (permalink)
patracy GA Chapter Vice President Join Date: Oct 2007 Location: Buchanan, GA Posts: 1,552 patracy's Truck Pics	My WVO system for the 24V (Waste Veggie Oil) Just documenting my WVO setup I've constructed for my 1999 Cummins 24V with the VP44. I should state that I'm not going to run this as a 100% WVO setup. I'll be running a percentage of diesel fuel or Kerosene in the tank with the WVO as well to help reduce the coking effect WVO can have. In any case I've constructed my system with K.I.S.S. in mind. Not so much in overall complexity. But in components. I'll start with the tank first. It's a plastic marine tank. It's 23 gallons. It fit inside my toolbox. I wanted to be able to have everything hidden out of sight. Best of all, it was only $33. I did have to clean a layer of varnish out of it (lacquer thinner works great!) and I had to replace the sending unit. I picked up a sender from the local marina shop. $33 for it. I used a Mallory 4060FI fuel pump for the WVO setup. You can get away with a typical vane style pump for diesel. But WVO is to viscus for a vane pump. The oil will cause the vanes to "stick" in place and stop pumping. The Mallory fuel pumps are a gearotor style pump. So they use a gear to pump. I used a series of fittings to step it up to 1" NPT into a goldenrod filter. The goldenrod filter is nice since it's clear. I can check on the filter media. One of the worries with WVO is polymerization. A traditional screw on cannister filter wouldn't allow you to see this in that event. Next I stepped it down to a tee with a adjustable pressure regulator. This bleeds off excess pressure back to the tank. From that point the output from the pump/filter/regulator/tank is fed into my hose in hose setup. The hose in hose is a 1" ID hose with 1/2" aluminum fuel line inside. I drilled out the center of the 1/2" compression fittings to seal them off. There are tees at both ends to allow coolant to pass through. This allows heat transfer. The key to WVO setups. The total length of the hose in hose is about 15ft. So the fuel is heated plenty by the time it reaches the engine. Here's the end that meets the engine. I fastened the hose in hose along the frame rail. Also I used a 5/8" heater hose for the return. I tapped off the head for the heat supply. I used a ball valves to adjust flow. It's also a good idea to valve off the coolant flow in and out in the event you have a leak. The return line is tied back into the heater core return. Here's a pic of everything plumbed as well. On to the engine itself. I used a pair of 1/2" check valves. Most people use expensive valves. But in my opinion that's a more expensive means to do so. And leads to failures. I used a 4 way fitting to allow for a port for my fuel pressure gauge and my warning light as well. While I was working on all of this I upgraded my diesel fuel system as well. I used 1/2" fuel lines with a 1/2" draw straw. I used AN fittings I picked up from summit racing. I used the 12mmx1.5 to -8AN adapters. And 90def -8AN fittings. The VP44 The new fuel pump for diesel Now for the return. Since the dodge is a return system. You have to have a selector valve for the return. Now about the return valve. Since I've got a dual pump setup with check valves. You have to have a delay to keep the selector valve feeding back to the WVO tank for purging. Otherwise you'll pump the WVO from the IP, injectors, and lines back into your diesel tank. I built a timer based off the 555 chip. Crude looking inside, I know, but it works. Here's a video of the controller in action cycling through sources and a purge cycle. YouTube - WVO controller with purge cycle Since I don't smoke I used the ash tray for a holder for the controller. Also notice the fuel gauge. All said and done I've got about $500 in my setup. So in about 5 tanks it'll be paid for. Hope this helps. __________________ 1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan. Parts to come: 150hp sticks, turbo, and bigger exhaust. Last edited by patracy : 07-13-2008 at 04:57 PM.

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07-13-2008, 04:40 PM	#2 (permalink)
patracy GA Chapter Vice President Join Date: Oct 2007 Location: Buchanan, GA Posts: 1,552 patracy's Truck Pics	If anyone is interested I can tell you a little more about the wiring. There's quite a bit of wiring to all of this. __________________ 1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan. Parts to come: 150hp sticks, turbo, and bigger exhaust.

07-13-2008, 08:47 PM	#3 (permalink)
Joe Reitman Cummins Fanatic Join Date: Aug 2007 Location: North Georgia Posts: 152 Joe Reitman's Truck Pics	Very detailed write up. I hope it works great. Too much work for me though... Where did you find the 23 gallon tank for $33? Thanks. __________________ John 3:16, John 14:6. Silver 6/06 Mega Cab Dually, G56, 2wd, 3.73, Gooseneck, Iggee seat covers, Tekonsha Controller, Opti Lube Summer Blend, Mopar Tailgate Spoiler, Rokktech '03 KX250/310, '01 KX500

07-13-2008, 08:53 PM	#5 (permalink)
patracy GA Chapter Vice President Join Date: Oct 2007 Location: Buchanan, GA Posts: 1,552 patracy's Truck Pics	I'm certain someone will ask. The black pipe for the heater will be getting a brace. I've got it already cut and drilled. But I just moved and haven't ran my 220V outlet for my welder yet. (I've been asked this on the other forums I've posted this on) __________________ 1999 2500 4x4 Club Cab Sport. ADRENALINE/pulse BHAF, full set of gauges, FP light, Holley Blue pump, 1/2" big line kit, Draw straw, 3" glasspack, TC lockup switch, Stealth VP plate, Heated WVO setup, poor man's 'pane setup, BD TC, BD VB, Billet input, Derale pan. Parts to come: 150hp sticks, turbo, and bigger exhaust.

07-14-2008, 03:41 AM	#6 (permalink)
Challenger Cummins Fanatic Join Date: May 2008 Posts: 153 Challenger's Truck Pics	Looks like a system that will work.I wonder if the wvo would pass through the filter easier after it is heated,how long until the first test run? __________________ 96 Dodge CTD 3500 4x4 black extracab dually auto 3.54 no mods 1980 Mack Cruise-Liner Cummins N14 370/430 hp 10spd,air ride

07-14-2008, 06:21 AM	#8 (permalink)
speed185187 Cummins Enthusiast Join Date: Jun 2008 Location: Newport News Posts: 252 speed185187's Truck Pics	nice setup, I'm working on an 86 gallon aux fuel tank from an old truck tool box. Still in the prep stages. Also picked up 120 gallons of WMO that's actually really clean. I get it from the navy auto shop here in norfolk. Really clean stuff. I have to finish sanding the tank and install pipes, bolt it to the bed, set up my filtration setup. Gravity drain from a 55 gal drum through 20micron - 10 - 1. With magnetic filters on all three. Aux tank will have a valve between the aux tank and truck filler with a flow meter. Open drain for aux tank to fill normal tank with varying amounts of WMO when i fill up. I'm going to start off with a 50/50 mix and see how it runs, than go up from there. __________________ 00 2500 2wd ext cab, SB. (BHAF, silencer ring MIA, Boost, EGT, FP Gauges, Breather bottle relocate, Fass 150/150, Fireball 150's, VA smart box, 4" exhaust) 03 Jetta TDI 5 spd "See tdiclub.com for all mods"

07-14-2008, 06:36 AM	#10 (permalink)
speed185187 Cummins Enthusiast Join Date: Jun 2008 Location: Newport News Posts: 252 speed185187's Truck Pics	I also bought a walbro pump for a pusher pump setup. Will be wired up with a relay off of the stock lift pump. Fuel/oil ratio is going to be measured when i drain the wmo from the aux tank to normal tank with something like this Tuthill Digital Flow Meter — 1in., Model# 820 \| Control Valves, Meters + Nozzles \| Northern Tool + Equipment __________________ 00 2500 2wd ext cab, SB. (BHAF, silencer ring MIA, Boost, EGT, FP Gauges, Breather bottle relocate, Fass 150/150, Fireball 150's, VA smart box, 4" exhaust) 03 Jetta TDI 5 spd "See tdiclub.com for all mods"

07-14-2008, 06:54 AM	#12 (permalink)
speed185187 Cummins Enthusiast Join Date: Jun 2008 Location: Newport News Posts: 252 speed185187's Truck Pics	I'll be working on the tank some more this afternoon when i get off work. I can snap some pictures then of the parts laying around. When I get everything set up, the truck should be getting the equivalent of 45mpg on D2. Depending on how much WMO i'm running. I'm also building a Biodiesel processer for my VW TDI. I've got a steady supply of 40gallons/week for WVO to process for that. My car will go well over 700 miles on 15 gallons so i'll have some left over for the dodge to drink. __________________ 00 2500 2wd ext cab, SB. (BHAF, silencer ring MIA, Boost, EGT, FP Gauges, Breather bottle relocate, Fass 150/150, Fireball 150's, VA smart box, 4" exhaust) 03 Jetta TDI 5 spd "See tdiclub.com for all mods"