I'm working on an 87 wagon that sat in the weeds for a couple years. After firing it up and running it awhile, it started developing fuel leaks in the fuel pump area.

Upon further inspection, I discovered the fuel return nipple on the gas tank had disintigrated to a stub, allowing the hose to come loose, and allowing the fuel to leak. I was able to cap off the nipple, but there is not enough left for a solid clamp/hose connection.

The best case would be to repair the nipple somehow. I've thought about sliding an oversized fuel inlet over the stub, and using some sort of adhesive. but I wonder if that will hold up.

Any ideas on making the repair without removing the tank? Or a sealant that will hold up to gasoline?

thanks, John

Shooting from the cuff here, but what about JB weld? I can't imagine it would be succeptable to fuel... but I haven't tried it either.

 

Just a thought.

cut and weld a new nipple on there...HA HA!!!

 

if you know what you're doing in terms of getting the gas fumes out of the tank: cut if off or seal it off and drill/tap a new hole and screw a fitting in place. as a matter of fact i don't know what this nipple looks like but you maybe be able to tap the inside of the nipple and thread an insert inside of it. but then you reduce your ID.

 

if you drain the tank and let it air out you should be able to weld something on there. but don't do it unless you're confident all the fumes and such are gone and you know what you're doing.

 

i'm sure i'll get bombarded for this, but in my experience short cuts don't have near the rigidity of a job done right. JB weld is good.....but wouldn't expect long life or high miles out of the repair. i've had JB weld do some really cool stuff, i've also had it fall apart over long periods of time. i avoid it now, or consider it a temporary solution and would never use it on someone elses car.

If the tank is in that bad of shape, you may just want to get a decent condition replacement.

 

-=Russ=-

for all the eh, fooling around, replace the tank.

 

by the time you get done patching that crusty mess together, and waiting for that inevitable moment....

you could just pull your tank, hit the yard, and be relatively sure its not going to

fail at the worst moment.

I've "gravity-drained" the tank, which is probably not sufficient for using heat to weld something on.

 

However, it may be possible to glue an oversized nipple over the stub that remains. I talked to a guy at NAPA that recommended an epoxy they carry that is specially formulated to work on gas tanks. I think I'm going to give it a shot.

If that fails, I'm gonna drop the tank and either repair or replace it. A hassle, but definitely the correct way to go. I agree that leaking fuel is not something to take lightly...

thanks, John

oversized nipple

(snicker)

actually not a bad idea