How to Add a Return Line to a Factory Fuel Tank

Today we're looking at how to add a return or a vent line to a factory tank that did not come with either. Its simple with this riv-nut style fitting. There are a few tips on how to do this and get the best result. Check it out!

#EFI #howto #returnline

[denniskwasnycia]

One thing that I do when drilling overhead to stop metal shards from getting in my eyes, is to take a microwave magnetron magnet, "donut ring" shape and stick it to the metal surface and drill in the middle, "ring surrounding the drill". This catches 99% or more of the shavings. This may be a way to stop metal from getting in the tank. Using this magnet with a hole in the centre and drilling with that in place, will do better than the grease for sure. .

[stuckinmygarage]

Over compressing that seal is key. Good reminder. These aren't under pressure like a fuel line to carb. Thank you.

[emilaznar]

Excellent "how to" video. Gave me the confidence to tackle this myself. thanks.

[Myles]

Well explained!

I got a little kick when you used a tape measure to make a random hole.

[classiclarry]

Nice, I needed this. My 89 f250 transfer valve failed and I've decided to isolate the front tank to feed the engine rather than fix or replace the valve (because it will fail again and send fuel to the wrong tank).
The rear tank I want to leave in place, wire its pump to a switch, and use it to refill the front. But, I did not want to plumb it into the return line to the front tank with the engine return line, even with a check valve I was afraid the fuel would still go to the rear tank and overflow. Now with this I can buy a new front tank which I need anyway, add this fitting, and I can refill the front tank at will and the two tanks are isolated with no valve to fail between them. This fitting will also be up near the vent, so no need for a perfect seal. Could also throw some Seal-all or JB Weld around it.

[waynew]

I have a picture in my mind of someone vacuuming out a tank that's not quite dry at all. There are videos of people sucking up gas with a vacuum. It's not pretty when those gas vapors get to that vacuum motor. EXCELLENT video though. Thank You.

[LockedAndLoadedx]

That looks like a good setup, be nicer if it had a drop line to keep from geyting as much areation of the fuel, especially in a Diesel application.

[REVNUMANEWBERN]

It appears it may be a all round better deal to put a return line fitting in the tube where you fill the tank

[jeffreystroman]

Modifying a gas cap to have a Schrader valve or air tool connection, or simply a rubber hose to the fuel line, a decent pressure regulator set for like 5 or ten psi will create just enough positive pressure to eject all the metal debris when making a hole in the tank. Not as much fun as a 9mm but you'd have two holes that way

[Meche]

More professional than what I did. '67 Mustang, added a PVC "Threaded Barbed Elbow" to the fuel filler line, <$1.00 with a band clamp.

[JRMny-nlut]

Cool- this is the first time I saw the grease tip. Thanks.

[Noscams]

Exactly the video I was looking for. Thanks!

[Jonnosummit]

I'm crazy about rare-earth magnets. I'm thinking of using the grease but also stick a couple magnets to the step bit also to grab those metal shards. I stick those powerful magnets to my oil filters as well. I also stick them to various grounded bolt-heads in my engine compartment to stick voltmeter connectors to or on the cowl or fender of a car I'm working on to hold tools or paperwork. They're handy little guys. That's why I'm crazy about rare-earth magnets.

[frekkledipped]

You also might try drilling upside down with a shop vac going, maybe tape the vac close to the area

[mickibbett]

Like the idea with the tape I used a washer! Regards Mick

[garycarbonneau]

Magnetize the bit and use just a smear of grease! You will be surprised how little if any filings are lost in the tank!

[dgambrel]

I use a dry tank, obviously and turn it upside down and use grease the few I've used. Then take a pick and paper towel and pull it around. Worked so far. It's some aggravation

[bcworkman]

GREAT VIDEO! I was wondering if you were going to cut yerself on that sheet metal edge.

[kevinbender]

great video, question. i cant seem to find any information if the vapor return line should enter fuel tank high or low. also should it enter in tank in the fuel or above the fuel?

[Ares-jxep]

Step bits are terrible for dropping chips, The grease trick works far better with a reg bit because the spiral taper naturally pulls material away from the workpiece.