Fuel Tank Cross-Over Revisited....New Parts!
Richard Oben recently brought up a post about this subject, and posted up some part numbers of some very nice rubber seals to use for the cross-over fittings in the tank. We are right at the point of doing this on a new build here, so I ordered up the parts he recommended. While we were at it, I got to thinking about an additional solution that takes care of yet another problem. Since all of the new kits are sent out with a programmable fuel gauge, all of the fuel ports and sender in the GTM Driver's side tank are completely useless. With this being the case, all of the fuel ports normally need to be plugged off, which means you have to find some way to plug them...which means searching around for something appropriate to plug them off with that will hold up to gasoline. I decided to kill a few birds with one stone, and just make an aluminum plate to replace the sender/jet-pump assembly, and put the AN fitting right in that plate. Now, no need to drill a hole in the tank at all, and no need to figure out how to plug all of the extra ports on the original assembly. The original bolts and rubber tank seal are used for the new plate, so nothing else is needed to seal this up......it seals up to the tank exactly as the OEM plate seals up!
I know there was some interest in having Richard make up a kit, and at the time, I agreed with him that it would be cheaper for everyone to just buy direct. I don't want to step on anyone's toes.......but......I suppose if there is a demand for these parts that I'm making here, I could provide them along with the seals from McMaster Carr. So, here's a break-down of the kit I could offer here. It would consist of (qty 1) of the aluminum plates as described above, to replace the "guts" of the GTM driver's side tank (with the hole for the AN fitting already cut into the plate), (qty 2) aluminum washers (made by me) that fit the AN fitting and the square-cut O-rings, (qty 2) of the square-cut o-rings, and (qty 2) of the Pressure Sealing Washer (the stainless washer with the rubber seal moulded into the washer).
The Pressure Sealing Washer would go on the AN fittings and seal the AN fitting to the tank on the GTM passenger tank, and seal the AN fitting to the aluminum plate on the GTM driver's side tank. The square-cut o-rings would then go on the inside of the tank, followed by the aluminum washers and the nut. The square cut o-rings inside the tank are not needed to seal, because the fuel is going to follow the threads to the outside of the tank anyway.....but IMO, they are needed to take care of any differences in tank thickness and provide constant pressure so that the pressure sealing washer can do it's job, and constant pressure against the nut, so the nut can not loosen up inside the tank.
The pressure sealing washers are fairly pricey little items!! My cost from McMaster Carr with shipping on these and the square cut o-rings is going to run me about $35 per kit. The Aluminum Plate is 1/8" thick as well as the 2 aluminum washers. The cost of the whole kit would be $55 plus shipping......just checked and it looks like the plate will fit into a USPS Small Flat Rate box, which I think is $5.50......so a complete kit with all the parts you need would end up being $60.50 including the shipping.
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