1G Broken Fuel Tank Evap Line Repair Ideas (FWD)

[97egl]

Busted the evap line on my fuel tank. I had already JB welded it a while back but the line was so crusty it snapped off. Looking for ideas to repair. I have an idea but figured I would see if anyone else has anything better.

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[steve]

Stealing from an earlier thread https://www.dsmtuners.com/threads/fuel-tank-repair.525291/

Can you reach down into the tank to tighten a bulkhead fitting like that?

Could you just drill and tap for a threaded nipple?

 

[waltah]

Steve's ideas look good if you have solid metal close to the hole -- the AN fitting would be much stronger in sheet metal like that though I don't know what access from the inside would be like.

If the situation isn't that good -- I've got no idea where that vent line goes in relative to any hole you can get a hand through -- then consider getting a piece of sheet tin the same or next heavier gauge as the tank and 2-3 inches square -- whatever will fit on that area. Scrape/scrub that area to clean metal and do the same on your patch. Shape the patch a bit if necessary to get the closest possible fit. Drill an undersize hole (like maybe 3 mm diameter) and then ream to a tight fit on the pipe -- might even turn the reamer backward the last few turns to spread the patch hole (rather than cut) to fit the pipe with extra metal around the hole.

Braze or silver solder the tube into the hole. There are low temp high strength solders that are used by gunsmiths, etc. -- tin/lead soft solder isn't strong enough. CLEAN FANATICALLY afterward because the fluxes are all highly corrosive. Spray some zinc paint on the top as rust will start right away if you don't. Bottom should remain nude.

The true fanatic would turn up a tab on one edge of the patch, wrap it over the pipe and silver solder that too.

Check fit -- you might need to dimple a bit around the hole in the tank. There's at least one JB weld product specifically intended for use with gas tanks; use that to glue the patch and tube in place.

Why yes, I've been very cheap for a very long time. Why do you ask that?

 

[AWD-Tony]

Drill it, install a rivnut, jb weld to seal it, install threaded barb and use a hose. Idk if there’s enough clearance. It’s just a thought I had.

 

[bling5tatus]

I would just cut a small square out where the tube broke off and weld a plate w/ a new nipple on there. It's a simple fix that would hold for many years into the future.