I need to put a return line in my stock sender, I was going to drill a hole and jb weld some tubing in sender.

does it matter were i drill the hole?

also how far down should the return go?

thanks
Bill

yes drill a hole anywhere you have room
I would braze or solder the tube 3/4 to almost all the way down
to keep the gas from making bobbles
ps (I don't like JB on anything) I just don't
some people do tho
Larry

I agree JB weld is not good, especially for this application. I would solder the return as it takes alot less heat than brazing. less chance of damaging your sender that way.
also a good idea to run the tube fairly deep and away from the fuel pickup. you dont to aerate the fuel,especially near the pickup.

I'm going to have to ask why, is this a 69 with a rochester?

Just buy a new sender with 2 lines on it for an SS, your going to have to pull the tank anyway to get at the sender to drill a hole.

Mine is JB-Welded and only extends an inch or so into the the tank with no issues. Sorry I don't have a pic. You pretty much just have to position it so that it doesn't block your sending unit electrical connector or hit any part of the underside of the sending unit. If you rough up the sending unit on both sides and your tube it should not be an issue. I picked my tank up by the new line when it cured. If JB-Weld is completely fuel proof and can be used to repair a cylinder I don't know why it can't be used for a gas tank. I also used it on the poorly tapped NPT ports on my fuel regulator that I couldn't get to seal off.


I searched FI forums for hours looking at the arguments for submerging or not submerging the line. If it is submerged it is supposed to be away from the pick up so as not to create eddies around it. Since it's pretty much impossible to put it in the sending unit where it would be submerged, not point near the pickup, AND still be able to get the thing in the tank I just dumped it.

I hereby retract my comments on the JB-Weld. Mine let loose yesterday right after filling the tank up. Since I recreated the line from the sending unit to the hard line and am using the hard line for the return, I think it was just flexing too much and released from the tubing. I probably didn't do a good enough job cleaning the coating off of the tubing I used. It is still locked on the sending unit though. If you're going to do it, I think you'd have better luck just making an elbow that extends back a few inches.

I've got another sending unit on the way and a couple different bulkhead fittings. I've read somewhere you should try to keep the return the same size as the sending line so I didn't get the sending unit with the 1/4" vapor line.

At least it was easy to drain the tank. Just hooked a ten foot piece of 3/8" tubing to the return, stuck it in the Durango's tank, and let the car run until it shut off.

Here's the easiest route:
http://www.moroso.com/catalog/categorydisplay.asp?catcode=32029

Here's the easiest route:
http://www.moroso.com/catalog/categorydisplay.asp?catcode=32029


Alas....on a '69 that would require a level of butchery which even I am not capable of making myself do. Plus my sawzall has a restraining order.

I put a return line on our 68 Camaro tank.
I used a dash 6 AN bulkhead fitting with a Stat-O-Seal, put it in the front wall of the tank, on centerline.
David

Oh, yes, it would be butchery on a '69.......no year mentioned, so I thought it was an earlier year.........Polysilfide, MIL-S-8133, is the sealer military avaition uses to seal fuel tanks.

I put a return line on our 68 Camaro tank.
I used a dash 6 AN bulkhead fitting with a Stat-O-Seal, put it in the front wall of the tank, on centerline.
David


Yup. Pretty much what I was thinking about doing and the fittings are on their way. Seems like I can buy just about anything but time these days. Need a heap more money for that.

Oh, yes, it would be butchery on a '69.......no year mentioned, so I thought it was an earlier year.........Polysilfide, MIL-S-8133, is the sealer military avaition uses to seal fuel tanks.

Cool, thanks. I think it was mostly my error. The tubing I used was the poly coated type and most likely I didn't clean and scuff it good enough. The vent tube I put in the filler neck is still in there good.

i had to run a return line to my tank in my 68 camaro for my efi lt1. you dont need to drill anything and the T in the fill neck will need a hole in the floor and gas can leak into the trunk of the car . i used this new sending unit http://www.summitracing.com/parts/RSD-FSU6702/ came with seals. i ran a external pump with 6- an line for the supply and the exsisting steel line for my return just got some hose fittings and did it at the tank.