Leaking gas tank (sending unit) after 16v 1.6L swap

[Wyld Bill]

Anyone else have this problem? Ever since I swapped in my 16v motor with the sending unit from the Tracker when I have more than 1/2 a tank of gas & tip the rig at all it leaks some gas down over the gas tank. :(
I dropped the tank twice now & tried sealing the mounting ring with chemical products suggested by others. They didn't work :mad3: So what have others done? If I hadn't used such a large hole saw to make the hole in the Samurai tank I would expand the hole into the mouning ring to get it to stop leaking. I might have to weld all around the ring instead of just the spot welds :rolleyes:

[Wyld Bill]

Btt

[sj-x]

i don't understand what you're talking about...

you cut a hole in the tank, screwed, siliconed in the 16v unit, and now it leaks?...
well... ya.. it will... why didn't you take whole tank? or use an inline pump...

when you screw it down, it's warping, then leaking..

if you weld do be careful to drain it out, put ahose in it for an hour or so and let it flush out, it will blow up otherwise

[Wyld Bill]

i don't understand what you're talking about...

you cut a hole in the tank, screwed, siliconed in the 16v unit, and now it leaks?...
well... ya.. it will... why didn't you take whole tank? or use an inline pump...

when you screw it down, it's warping, then leaking..

if you weld do be careful to drain it out, put ahose in it for an hour or so and let it flush out, it will blow up otherwise
When I did it this is how most were doing,...now you make it sound like I was an idiot to do it that way :confused:
I didn't want to take the whole tank because it's almost totally different than the Samurai tank. I didn't use an in-line pump because I heard a few bad things about them & figured on a high pressure MPFI sysstem the stock pump & fuel filter would be my best bet.
It was warping at first but I ground the screws down so they are just long enough to go into the mounting ring but not through the back of it.

[Wyld Bill]

I think I'm gonna try filling the tank up with water & welding all the way around this mounting ring.
http://www.fototime.com/3354B029D45F14D/standard.jpg

[szki272]

From looking at your pix. It looks like it would leak between the flange and the tank. As well as around the screws holding the pump in place. Sealant seems to work best when between 2 surfaces, but doesnt work well when placed along the edge of a part


I would suggest pressurizing the tank (low pressure)and using window cleaner to look for leaks. I had the same problem. I drilled the hole too big so I welded the flange and warped the flange. I filed it flat still had leaks so I used some gas resistant sealant and that took care of it. The sealant is blue and doesnt dry.

I welded around the inside of the ring. since if you weld around the outside the gas can leak around the screws. it looks like you just tacked the ring around the outside. On the factory tank the seal isnt actually at the ring. The seal is formed by the sheet metal of the tank being flared up inside the ring making contact with the seal on the pump. Also I have found that my pump isnt sitting on the bottom of the tank. It starts sucking air when I still have 2 gallons left.

[Wyld Bill]

Yeah I'mhoping to get some weld on the inside of the ring. I know what your saying aobut the stock Tracker tank being flared up in the middle. I wish I would have drilled the hole in this tank smaller then taken a muffler expander to flare it upwards.
I'm surprised you warped the ring by welding it,..did you do one constant bead around it?

[TatorZuk]

I used rivets on mine...Rightstuff sealant underneath the ring...and the factory gasket between the ring and sender.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=185306&stc=1 http://www.pirate4x4.com/forum/attachment.php?attachmentid=185305&stc=1

[Wyld Bill]

I used rivets on mine...Rightstuff sealant underneath the ring...and the factory gasket between the ring and sender.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=185257http://www.pirate4x4.com/forum/attachment.php?attachmentid=185258&stc=1
I can't see the dam pics ARGHHH!!!!! :mad3:

[TatorZuk]

I can't see the dam pics ARGHHH!!!!! :mad3:


I think there back now.

[Wyld Bill]

Oh no chit. Heck that seems like a good idea. I'll see if I can find some of that stuff.

[samuraiman]

Hey,

I took mounted the ring on and put and o-ring under the flange and the factory rubber ring on top and ran long self tappers through the hole and snugged em up not too tight. Also I had a freind just lengthen the tube on the stock fuel pump to reach the lower end of the tank, sucking air is hell on a fuel pump.

[Wyld Bill]

Hey,

I took mounted the ring on and put and o-ring under the flange and the factory rubber ring on top and ran long self tappers through the hole and snugged em up not too tight. Also I had a freind just lengthen the tube on the stock fuel pump to reach the lower end of the tank, sucking air is hell on a fuel pump.
Huh? Got any pics? So you went through everything with self tapping screws? Yikes :eek: I do like the O-ring idea though. I might drill out my welds through the mounting ring, set a thin O-ring on the opening in the tank, RIVET the mounting ring on OVER the O-ring. The rivets should pull the mounting ring down tight enough to squish the O-ring & prevent leakage.
:)