New fuel tank, how to cap the return line ?

[flx]

Hi,

The fuel tank on my 1974 FJ40 was in not so good condition so I ordered a brand new one from Toyota. As for a lot of parts, the version available has all the options, so a fitting for the return line and the 3 outputs for the evaporator.

My Euro-spec FJ40 came without a return line and without an evaporator so I need to cap all of that. For the evaporator lines I'm not too worried because they are on top of the tank.
But the fuel return fitting is right in the middle so will have a permanent contact with gas and a bit of pressure applied. It's also right in the way of the center passage between the front seats (and we regularly use it to access back seats) so it needs to not protude too much or be too fragile.

What would you use to securely cap that ? Really don't want to have gas leaking in the cab...

I found things like that in silicone that paired with a collar seems a good way to cap it but they are not indicated for fuel (the ones I found at least) so not too sure if it would last :

(the best I found are rated for fuel vapors)


On the other side I found those plastic things that are rated for a chemical resistance against fuel but not too sure about the risk of it coming lose (particularly if some one bump on it) :

Or maybe the better is simply to loop a fuel hose between the fuel return fitting and one of the evaporator fitting ? (But definitively not the most elegant on the cab)


What do you think ? Someone else had the same issue ?

 

[brian]

Short bit of hose and a bolt.
Clamp hose to tank with bolt clamped in the other end.
I have this on mine...no leaks in 6 years.

 

[SteveH]

You could install small metal caps and braze them onto the nipples. This would require brazing skills, but would be very fuel/vapor tight.

If you use any sort of rubber cap, be sure it is of high quality. The Chinese-made Dorman-brand garbage sold at auto parts stores will rot and fall apart in a year or two.

 

[flx]

Thanks for the answers !

Short bit of hose and a bolt.
Clamp hose to tank with bolt clamped in the other end.
I have this on mine...no leaks in 6 years.

I actually stumbled on the same trick on a Porsche forum during my research before to post. I definitely keep the idea in mind if I don't find better but I hoped for a cleaner way to avoid the bolt dangling around in the cab.

You could install small metal caps and braze them onto the nipples. This would require brazing skills, but would be very fuel/vapor tight.

If you use any sort of rubber cap, be sure it is of high quality. The Chinese-made Dorman-brand garbage sold at auto parts stores will rot and fall apart in a year or two.

I will see for the metal cap and brazing, at first my mech was not very thrilled with soldering the inlet but seems a better idea with a metal cap over.

As for the cap the better I have find until now are from a company called Redox and are made of VMQ silicone and polyester fabric support (maybe not translated properly). But officially it's only rated for gas&oil vapors, not too sure if they will last in direct contact with gas...

 

[flx]

Or... I use the plastic plug listed in my first post and rated for a chemical resistance to fuel + a silicone cap over, held by a collar on the inlet.
Should not leak with all of that in the way, no ?