2G Welding A Fuel Pickup/Sending Unit

[gijoe985]

Hey guys, curious how you would skin this cat?

My students cracked the line coming from our 1995 gsx fuel sending unit, where it sits on the tank. I've already cut, bent, and flared a piece of 3/8 tubing to replace the broken one, but I need to figure out how I want to attach it. We've got everything from mig, oxy, brazing, soldering... we've got options. Just curious which route you'd go.

I've also never welded on something that has been exposed to gasoline before, so I figure we'll take it out, remove anything that is not metal, and heat the whole thing up to hopefully remove any impregnated gas.

 

[FIBA M - EC17PSE]

Firstly wash it fully, its zinc plated so where ever you weld you want to remove that in said area and cover up as the excess fumes will smell and dont want to breath that stuff in,

Its not a hard job really, but if you dont want to weld then i might say get a bulkhead fitting but then you need an AN lines which might not be the route you want to take yet,

Recoating after can be simple as just a spray can job to protect it from elements.

Thats about it really, its a pretty simple job and can be tig or braized which ever you find easier to do

 

[99gst_racer]

gijoe985 - Got a pic? Is the old line cut flush? You have to be careful with heat on these as if it's gets too hot, it can release the solder that holds the OE tube in place.

I've never tried to reattach a tube to simulate the OE configuration, but I've welded on plenty of AN bungs on them. Just a quick media blast, TIG weld on being very mindful of the heat, and then a quick coat of paint. And that's it. But this might be an option for you. If you aren't interested in using AN hose/fittings, it could be adapted back to the OE fuel line right there at the tank. Just an idea.

https://www.dsmtuners.com/threads/fuel-line-setup-an-fittings-on-sending-unit-2g-awd.432095/

https://www.dsmtuners.com/threads/fuel-sending-unit-to-an-fitting.370847/

 

[dustyboner]

silver solder with a little brazing flux will also work

 

[1990TSIAWDTALON]

You could do something like this
https://stmtuned.com/products/stm-8an-fuel-bulkhead-fitting

My son did his 95 Talon with that fitting this weekend.

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[motomattx]

Or this:

https://www.summitracing.com/oh/parts/icb-an861-08-31a/overview

 

[gijoe985]

So, I brazed the tube in. 3/8 hard line bent to match. I really wanted to do the AN fittings, but I also just want to see this thing run (we've had it for 3 years, got it running last week for the first time and then had a gas leak.) So I just used what we had available.