I want to show how I do a fuel return or pickup line on a fuel sender to add EFI or reroute fuel lines or a vent. Follow along….I’ll show you the simple safe and easy way to do this with commonly available tools. Now is probably a good time to mention working on gas tanks is something that should involve impeccable safety manners. Not sure how to keep from blowing yourself up with gasoline? May well be time to learn.
Here is the removable sender/pickup piece that removes from the gas tank. In this case, the fuel level sender is no longer here as it was moved to another spot on the tank. No matter. I need a second line on this one. Drill a hole. I did a 5/16″ hole intending my 3/8″ tube to fit once flanged. Then, we need to flange the hole a bit to make some surface area for some silver solder to adhere to. Flanging it makes this joint between tubing and the metal of the sender much stronger. That’s why the factory does it that way. Here’s how I get this important task done. The shank on a punch and a socket to support it.
Smack the punch a few times with the socket on a hard surface like a vice or anvil to dimple it in a tad and make it so the 3/8″ tubing fits nice and snug.
I bent this 90 deg elbow on my tube and figured out how long I needed it to be so it would pick up all the fuel in the tank. I set it up so it would be 1/4″ from the bottom. I slipped it thru the sender piece and bent the bottom end to where I wanted it. I had sandblasted the parts as well to get them clean in preparation for soldering.
Here is the whole thing set up the way I wanted it to be….hey…what is that STUFF on there? It’s soldering flux. The exact same stuff used for soldering copper plumbing together. It’s a mild acid for cleaning the surface. It’s absolutely essential for getting a good bond. Try and not wipe your eye after getting any on ya. K? If you have any cuts, this stuff will find em….oh yes….
On to the soldering part! I use this silver solder. Again, it’s sold in plumbing supply places and hardware stores.
Here is where I mention that parts that have touched gasoline need cleaned very well so you don’t blow yourself up. Maybe also don’t have the torch going right atop the gas tank right? Do this WAY away from the gas and the fumes that can travel a ways along the floor. Don’t go BOOM. I used a ordinary propane torch to heat the part so the solder will flow into the little flanged spot the tubing is thru. Torchy-torchy!
Sorry I can’t take pix and add solder at the same time…..but you know where it needs to go. Once done, I sandblasted it, used some spray carb cleaner to blast the sand off and out of the tube so it doesn’t ruin my pump. Here is the finished product.
Add a fuel strainer and go. If you were just adding a return, it really only need go into the tank a few inches. Reinstall and check for leaks. Enjoy!