drilling a hole in the tank

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diymirage

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just spit balling here

but im thinking on redoing the return nipple on my fuel tank
(I'm hoping I can drill out the sending unit and put a larger bulk head in)

but if not, can I just drill a hole into the tank ?
how do I keep the shavings from dropping in?
 
If the tank is out, I rolled it on it's edge, sending unit down, drilled the return hole next to the sending unit and used a magnet to collect the partials that went into the tank.
 
I would not drill it. Get a nice heavy duty awl. I have on goes out nearly 3/8". Rotate it and carefully sharpen it up to a sharp point and just drive it in, wiggle, drive in some more, wiggle, etc. This makes a "large" "rolled" edge that gives you more surface area for solder/ silver braze/ whatever

........Like one of these....

51ZZAmZE0vL._AC_SL1000_.jpg
 
if you do drill, you can put grease on the drill to catch some of the chips, or use a transmission pan magnet and drill thru the center hole, or combine both methods. Rather than use a twist drill, I'd recommend using a step-drill, they work much better on sheet metal like that, and drill a rounder, smoother cut hole.
 
Use a magnet to get what you can and anything you don't get - that's what the filter sock and fuel filter are for. I guarantee there's more crap in your tank than a few metal shavings.
 
I swapped my 5/16" to 3/8" pickup tube to keep my working OEM fuel gauge sender. Removed, reamed to 3/8 and soldered new tube in. Also agree the step drill is the way to go for sheetmetal.
 
thank you guys

the new return will be a brass bulkhead, so i dont know if rolled edge would be good

im hoping i can put it on the fuel sender, but its good to have a backup plan
 
just spit balling here

but im thinking on redoing the return nipple on my fuel tank
(I'm hoping I can drill out the sending unit and put a larger bulk head in)

but if not, can I just drill a hole into the tank ?
how do I keep the shavings from dropping in?

I did mine (3/8) in the sender and it worked out fine.
Laugh if you want, but I used the threaded sleeve and nuts like they put lamps together with, then soldered a brass nipple inside the 3/8 tube to connect my hose onto..
That and a couple of stainless washers with a couple of nylon washers for sealing worked out nice.
 
I decided to just knock out the 1/4 return on the sending unit and put the 5/16 bulkhead in there

it is a brass bulkhead, with some permatex #4 on it
that shouldn't leak, should it?

Resized_20200605_165942.jpeg


Resized_20200605_165948.jpeg
 
I silver soldered a 3/8's" steel line in place of the 1/4" return on an aftermarket sending unit.

I had to get the real silver solder from a welding supply company as all the fake silver solder seemed to be sold by the local chain hardware stores. It never leaked.

Sending unit mod 3.jpg


Sending unit mod 1.jpg
 
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