Fuel tank return line

[jchav62]

Has anyone ever plumbed a fuel return line to a stock tank, or to a tank that didn't have a 'return'. If so, how? What fittings did you use?

Thanks JC62

[Bugeyev8]

I did this by soldering a new line next to the pick up line, been working this way for 17 years, I can get some pics if you want of the installed unit, I did not take pics of the install

[61_FL_Apache]

Are you running a fuel system that needs a return line?

[jchav62]

Originally Posted by Bugeyev8

I did this by soldering a new line next to the pick up line, been working this way for 17 years, I can get some pics if you want of the installed unit, I did not take pics of the install

Pics would be awesome. Thanks.

[jchav62]

Originally Posted by 61_FL_Apache

Are you running a fuel system that needs a return line?

Yes. TBI.

[Bugeyev8]

I have been running a TPI for years, the first time I set up the tank I just ran a 3 inch long line which caused fumes in the cab, this time I ran the line below the fuel level and it works good, what fuel pump are you using ?

[jchav62]

Carter inline, designed for throttle body...

http://www.summitracing.com/parts/CRT-P5001/

[Bugeyev8]

What TBI are you running? I ran one in a 66 Buick with a 92 Camaro TBI and a friend has a GM TBI on a 74 Triumph TR6 with the stock engine, here is the best pic I have for you, I should have painted the sender after sand lasting it but...I never got around to it, I did not want rubber lines in the cab so I used a compression fitting on the return, its got no pressure so I figured it did not need a flare union, hope this helps

I bent the line the same as the stock feed line and then I used stainless saftey wire and my saftey wire pliers to support the new line to the old line, I used silver solder and a flux that appears now that I should have rinsed it with something as corrosion has formed, its the first time I looked at the tank in about 2 years

[jchav62]

Thanks for the pic! That's exactly what I was thinking of doing, but I wasn't sure how it would be fastened... I was thinking a threaded union with rubber washers, but soldering makes way more sense. Feel like making another??

I'm running a TBI setup from a '91 or '92 pickup...intake, throttle body, computer, harness. My brother's in law have been using this setup for awhile for TBI conversion, but they usually use a later model tank, which sometimes left the vehicle with a questionable gas gauge. What pumps do you guys usually run?

[1963nova]

another option ,which i did on my 66 GMC is to use current 5/16 line for return and add 3/8 line for suction. i jb welded new line in sending unit after running tubing to bottom of tank. i needed larger feed for big block mpi injection

[T Herder]

Here's the procedure I did when I fuel injected my 305
e V6.
Buy a new stock replacement fuel pickup and sending unit. Carefully remove the sending unit. Sand an area of approximately one inch diameter to bare metal on both sides of the new units mounting plate. Drill a 3/16” hole in the mounting plate and removed any burrs. Support the mounting plate on the internal side of the plate with a 9/16” six sided socket, the six sides towards the mounting plate. Take a 5/16” diameter tapered drift punch and drive it through the hole to form a tapered flare recess. This recess will be on the outside of the plate. Using a tubing bender, bend a 5/16” steel tube to parallel the fuel pickup line ending at the same bottom level BUT returning to the OPPOSITE side of the tank. Bend the external side of the return tube down to parallel the feed line. Carefully work the new return line through the 5/16” hole to what you THINK might be its final position. Then try fit it into the tank to confirm it will install with no problems. Once this is accomplished, Silver solder the 5/16” tube into the mount plate using 45% Silver solder.
If you’re hesitant to try this, practice first with a piece of scrap sheet metal and scrap tubing of the same gauge as your new replacement mounting plate.

Best regards,
Butch

[turbostar]

JC,my fellow NM chevy truck fan,do I have a deal for you.I am converting my 65 swb to an LT1 drivetrain and will not be using the stock gas tank. I have offered it free to any member on this board.Not only is it in perfect shape but has a new sending unit for the gage AND I have modified it with a return line. I have run it with the return line and it works perfect. Like I said,it is free to members of this board and my only goal is to see someone get it that needs it and helps one of these early trucks stay on the road. I'm sure it would be gone already if we did not live in such a low populated state. But for you the drive down to get it would be well worth your time.

[jchav62]

Thanks for all the info guys!!

Hey turbostar, I sent you a PM.