Relocating Return Fuel Line

[Strum]

I posted here a couple of weeks back regarding CV joint (drive shaft), brake rotors, and leaking fuel tank. I completed the first two (whoever told me the CV/drive shaft replacement was a dirty job was exactly correct).

Anyway, now for the tank. The return line broke off at the fuel tank (rust). Everything else seems to be intact. The location where it busted off the tank has no more additional metal to allow for reconnection. I certainly don't want to replace the tank for just that, so I was trying to come up with an alternative plan.

Instead of running the return line to the tank, why not run it to the fill pipe? A fill pipe is a lot cheaper, it can be removed and a new one can be installed much easier than replacing a tank (an assumption on my part). I was thinking of installing some kind of connection to the new filler pipe prior to installation, run a new rubber return fuel line to the fill pipe.

I've posted just about everything I know about repairing cars, so I know very little. Based on my limited background, this might be an off-the-wall idea. I don't know if there are any safety factors to be concerned with, or if there would be an issue when it goes in for an E-check.

Any thoughts?

[thisisntjoew]

Well from what I know I am not sure I support that idea...heres why... the return line is somewhat higher pressure line that returns the surplus fuel that isnt used by the fuel delivery system.
With your idea it seems that you would be creating a situation that will mix the gasoline in your tank and cause the EVAP system to be overloaded and cause other problems as well. The return line, as it existed, is designed to return the fuel "nicely" to your tank without creating any excessive problems(like an increase in gas vapors).
I would suggest looking into other options but be careful when dealing with the gas tank.

[Strum]

Originally Posted by thisisntjoew

Well from what I know I am not sure I support that idea...heres why... the return line is somewhat higher pressure line that returns the surplus fuel that isnt used by the fuel delivery system.
With your idea it seems that you would be creating a situation that will mix the gasoline in your tank and cause the EVAP system to be overloaded and cause other problems as well. The return line, as it existed, is designed to return the fuel "nicely" to your tank without creating any excessive problems(like an increase in gas vapors).
I would suggest looking into other options but be careful when dealing with the gas tank.

You brought up a good point that I would never have given thought to. If what you say is true, then it's back to the drawing board.

I'm trying to avoid dropping the tank because I am concerned with a chain reaction of problems once the tank is dropped. The other factor is the dollars involved if I have to install a new tank. I'm trying to cut cost without endangering my life or damaging the car.

[Strum]

Originally Posted by thisisntjoew

With your idea it seems that you would be creating a situation that will mix the gasoline in your tank and cause the EVAP system to be overloaded and cause other problems as well. The return line, as it existed, is designed to return the fuel "nicely" to your tank without creating any excessive problems(like an increase in gas vapors).

I keep on thinking about this and the only thing that you noted that I don't understand is the statement above. How does the original return location differ from where I am suggesting? What is it doing that makes it return "nicely' to the tank. Wouldn't my idea be the same as filling the tank at the station? The difference 1) the cap is on, and 2) it would be far less of a flow as compared to a station pump.

I'm not disagreeing with you, just trying to determine the actual risk.

[Strum]

thisisntjoew,

Well, I did a little more research and sure enough it's not a wise thing to do. I didn't realize that where the gas returns to the tank is so critical. I thought I found a simpler and less expensive fix, but it looks like I will be dropping the tank and most likely replacing it.

Since this is a 1993 northern Ohio car, the underside has a lot of rust (although the body is in great shape). When I drop the tank is it wise to assume that I will be or should be replacing all of the lines?

Is it worthwhile purchasing a tank from the junkyard? The problem that I have with the current tank is the rotting of the connections on the tank, so I assume that the same condition would only be a year or two down the road for the used tank.

Any tips on dropping a tank, besides the "don't smoke" or "don't do it by candle light". A couple of people have suggested having a shop do it because they was it's a pain in the a$$ without a lift. I have a friend that has a two point lift in his garage, but unfortunately his Triumph is on it with no tires or wheels.