Note - the adding of a fuel tank like this could be dangerous.
Do so at your own risk!

I debated whether I wanted to add my Tourtank to my Ulysses. I hadn't had
mine on my Connie since the Butt Lite 4 in 2006, and I generally
don't like running with an auxiliary fuel tank. It's one more thing to go wrong,
and up until this year, it mandated you run in expert class in the Minnesota 1000.

Three things changed my mind however.

1. The stock range on the Ulysses isn't very good. Fuel in the frame is great for
center of gravity and handling, but it really limits fuel capacity.  My low fuel light goes
on around 160 miles.

2. I'm planning on riding in a group IBA "Top Down" ride this spring. This is a ride from
Angle Inlet, MN to Key West, FL. That's from the northernmost town in the lower 48 states,
to the southernmost town. If I'm riding with someone with better fuel range (almost anyone would have
better range than this), I need to not be a drag, having to stop every 160 miles. Plus,
on timed distance rides, every stop means loss of time.

3. The Minnesota 1000 this year is actually a 2-day event (the Minnesota 2010). They've also
eliminated the class system, so everyone is competing against everyone else.  I'd be at a disadvantage
if I didn't run extra fuel, and since I expect much of it to be in the rural Dakotas this year, fuel
at night can be sparse. Extra range is a must.

So onto the project.  

I kept my old 3 gallon cell that I had on the Concours. Even though I could run a lot more
fuel with the smaller stock capacity on the Buell, I didn't want to buy a new cell, and I don't
like carrying that much extra weight. My range should still be around 280 which is plenty for me.

There's quite a bit of info out there on how to do this, thanks to the folks at BadWeb, but it still took
some thinking on my part. With the fuel in frame on the Buell, the best way to
plumb the cell, is to replace the drain plug on the fuel pump with a hose barb, and
fill the tank from below. The biggest issue is finding the right fitting.

The drain plug on the pump is a 3/16 O-ring Boss. Why they would use such an obscure
type of thread, I have no clue. I went to every auto parts store and farm store I could find
looking for something to fit. Finally, the guys at Central Hydraulics in Rogers, MN ordered me something
that would work (BIG thanks to them). It's actually a JIC fitting with the same thread pattern that will accept
an O-ring.  The opposite side is an NPT 1/8 male thread.

The elusive fitting.

So after trying a couple of things, I eventually went from the 1/8 male on the fitting above,
to an elbow fitting with 1/8 NPT female threads on both sides. Then after more searching,
I finally found a 5/16 hose barb with the 1/8 male NPT to go into the elbow. The hose barb
was also difficult to find, but I found one at the third hardware store I tried.

My first attempt actually used an additional adapter to use a 1/4 thread 5/16 hose barb, but when the bike
hit a pothole or bump, the 1/8 to 1/4 elbow would hit the frame where the oil is held. Not good.

(click on the photos to enlarge in a new window)

This shows the original fitting, with the additional reducer, but you get the idea.

Pretty much everything else was self-explanatory, or was easy to figure out
from looking at other photos on BadWeb.

I did discover a useful piece of hardware when I was replacing/fabricating the fuel pump
mount on our old VW Bug. They're conduit hangers, and they come in varying sizes. I've
only ever seen them at one hardware store, and when I've asked elsewhere, people
look at me like I have three heads.  In looking for a way to hang the quick disconnect,
the fuel on/off valve, and the fuel filter, I thought back to my other project, and realized that the
conduit hangers, in a smaller size, would be perfect for this project. I re-used the 
disconnect and fuel valve from the old bike, and added a new metal fuel filter.

(click on the photos to enlarge in a new window)

Disconnect and conduit hanger

Fuel valve and fuel filter with conduit hangers

Side rear view showing the mounting and vent line. Note the cool
stickers from previous rallies.

Bike in full rally mode, minus my seat bag and water jug.

.