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DieselAutoPower.com
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Discussion Starter #1 (Edited)
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.
 

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DieselAutoPower.com
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Discussion Starter #2
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.
 

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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.
 

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DieselAutoPower.com
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Discussion Starter #4
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. :rof

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.
 

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DieselAutoPower.com
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Discussion Starter #5
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)
 

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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?
 

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DieselAutoPower.com
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Discussion Starter #7
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. :lol3: (Kidding!)
 

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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.
 

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DieselAutoPower.com
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Discussion Starter #9
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?
 

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DieselAutoPower.com
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Discussion Starter #11

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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.
 

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That looks great. Do you turn off the stock lift pump when the WVO pump turns on? If so, how do you do this?
Thanks
 

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DieselAutoPower.com
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Discussion Starter #14
That looks great. Do you turn off the stock lift pump when the WVO pump turns on? If so, how do you do this?
Thanks
Yes, you wouldn't want the stock pump working as you'd be pumping diesel along with your WVO into the engine. My controller has a single throw double poll switch that directs power to the correct pump. I merely tap power off this to run the purge timer and power the fuel selector valve.
 

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I hate to be a pain in the , but, how do you switch the power between the 2 pumps.

Thanks
 

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Discussion Starter #17
well does it fire in your dura max?:rof:$::$::$::butt:
Yep, we've got one setup on a duramax as well. Works great. They've got a nicer FASS pump/filter setup though.

Once the old house is sold, I'll be picking up another DMAX. :thumbsup
 

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Got it.
Thanks
 

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Discussion Starter #20
Just an update. DO NOT USE A GOLDENROD! I thought the head of the filter was aluminum. Turns out, they're zinc! Zinc is terrible when exposed to diesel or WVO. The plating comes off in diesel fuel and passes to the engine. WVO causes polymerization at the head. Allowing the goop to pass on to the engine. In either case, it's not good! So I stopped by tractor supply and bought a cast iron head and a better filter. I noticed a few of the zinc flakes in the diesel fuel left over in the goldenrod today too. :(



I'm purely on WVO now. Truck is running great. Fuel pressure is rock solid at 22psi. WOT can only pull it down to 19psi. I'm going to pull my timer and do some cleanup on it. I need to install a voltage regulator as the timer sticks at times. I also need to dial in my purge to 2 minutes.

The wife thought the truck smelled better when I parked it in the garage tonight. :D
 
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