Fueling from plastic gasoline containors

I fuel my airplane about 3 times a month with about 40 gallons of
autogas. Plastic jugs are dangerous and a hassle if you need more than
5 or 10 gallons. If you invest in the right rig it is easy and safe to
self fuel. I saw an article (in Kitplanes?) a few years back about
building a little trailer with tank and pump. That would work for
anybody. If you have a pickup truck read on.

I carry my fuel rig in the back of my pickup and take it out when not
needed. A built-in toolbox tank is really nice but will cost you about
$300 just for the tank.

Recently I was visited by a representative of the County's Fire
Department Aviation Unit just after I finished fueling. My setup passed
his inspection and cost less than $500 for everything:

1) To carry fuel on U.S. Highways the container needs to be DOT
approved and labeled/placarded as flammable liquid. Failure to do so
violates Federal Law. I bought a refurbished 55 gallon closed head
steel drum that is United Nations and DOT approved for flammable
liquids. Cost me $25. Available free some places. Self adhering
flammable-liquid placards from Gemplers were 4 for $5.

2) Bought a 15GPM Fill-Rite 12volt transfer pump that is UL-approved to
pump gasoline. Cost me about $270 from Harbour Freight. It is designed
to mount perfectly into the top of a steel drum. I also purchased a 20
foot long anti-static fuel hose to replace the standard 12-foot hose
that comes with the pump for $25 from Northern Tool. Also added a
Northern Tool Goldenrod Waterblock Filter for $25. It gets all the
water out, traps particles larger than 5-10 microns and easily connects
between the pump and the fuel hose using 3/4" pre-threaded bronze or
galvanized pipe nipples from Home Depot for $5.

4) While at Home Depot I also got some gasoline tolerant pipe joint
compound, two 20 foot lengths of #12 stranded copper ground wire (green
insulated), some alligator clips for the ground lines and the pump
power connections to connect to the truck battery, a bronze ground
strap to attach the ground wires to the pump ahead of the filter. This
stuff was about $25. Also from Home Depot a good medium-sized
foam-type fire extinguisher (8A-70B rated) $35.

5) I strap the drum with attached pump permanently to a hand
truck/dolly using 5-foot nylon ratcheting strap ties and also use a
pair of 12-foot strap ties to secure the rig to truck bed tie-down
points. Cost for straps and dolly about $50. Also got a pair of ramps
made from 2x8 x 6-foot long boards that hook to the tailgate allow me
to wheel the drum up and down from the truck bed.

On days I want to fuel the airplane I wheel the empty drum/fuel rig up
into the truck bed and drive to a gas station just outside the airport.
I ground the rig to the gas station pump and my truck chassis and test
the gasoline for alcohol/ethanol using a Petersen $15 tester. I haven't
found any gas with alcohol yet but still always test. I pump between 35
and 45 gallons of regular into the drum depending on what amount I am
sure will completely fill the airplane tanks. I drive to the airplane,
hook-up the gound lines to plane, power lines to truck battery, pull
out my step ladder and top off the airplane as fast as the FBO could do
it. If there is any gas left in the drum after the airplane is full, I
pump it into the pickup fuel tank. It is much easier to move the drum
when it is empty and safer to keep it empty too.

In reality its a bit of a work to self-fuel but I save about $35 to $45
dollars every fill up. Much more important my 7:1 compression ratio
O-470 engine runs better on 80/87 octane. No lead fouled plugs and no
lead sludge in the oil. Oil analysis greatly improved since switching
to mogas. I'm Happy. Rig was paid for after 6 months.