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Weird Gen1 fuelTank Leak |
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oscarb2b 
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Joined: 27 Jun 2013 Status: Offline Points: 195 |
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 Topic: Weird Gen1 fuelTank LeakPosted: 01 Aug 2022 at 18:31 |
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Bit of a strange on this one. On the last trackday I noticed a puddle of fuel on the floor and traced the leak back to the drain nipples under the tank. But the fuel wasn’t coming out of the end of the nipple, but from the base of one of them.
I thought I may have disturbed something when I drilled them to clear the ducts a month ago but taking the pump out and having a good look and feel around inside the tank I can’t see that the surface has been broken. So I’m wondering where this could be coming from?! My other thought was that the drain pipes inside the tank could have failed and fuel was getting in, but then I don’t see how that could result in fuel coming from behind the nipple, around the base. Hopefully I’ve said nipple enough. Here’s some pics     |
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oscarb2b
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Joined: 27 Jun 2013 Status: Offline Points: 195 |
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Posted: 01 Aug 2022 at 18:37 |
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Picture 3 of the pipe inside the tank where it splits apart, there’s a small surface cut and you can see the (copper?) poking.
I’ve blown an air line in each of the drain holes but can’t feel anything in the tank itself, but I didn’t block the holes up at the filler cap so could try that next
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Bladerunner919
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Joined: 19 Mar 2020 Location: Bracknell Status: Offline Points: 405 |
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Posted: 01 Aug 2022 at 19:41 |
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Are you sure the leak isn't from where the pump meets the tank, and is just seeping to where you see it? If you put a straight edge across the bottom of the tank, is it straight and level in all directions? Mine (like many) was very warped and I had to heat it up and tease it flat to get a good seal. If you have to do that, make sure all the fumes are evacuated, of course!
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oscarb2b
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Posted: 02 Aug 2022 at 06:25 |
At the time the leak started, i was able to see the fuel dripping from around the base of the drain nipple. I was pretty sure that's where it was coming from but would need to rule the base of the pump out. I'll check how true the opening is and go from there. From memory the base of the nipples are slightly higher than the bottom of pump so that might be another sign it's not the pump gasket area
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Spoonz
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Joined: 11 Feb 2008 Location: North Devon Status: Offline Points: 10957 |
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Posted: 02 Aug 2022 at 10:00 |
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What condition are the o rings in on the nipples ?
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oscarb2b
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Posted: 02 Aug 2022 at 12:44 |
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I don’t know, will need to check.
One of the nipples’ thread was so seized it pulled the sleeve out of tank with it. But I think the leak was coming from the other one. So is it possible that the o rings would let fuel past? |
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Spoonz
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Posted: 02 Aug 2022 at 13:19 |
If the o rings are compromised then fuel that gets past the threads can leak out around the base of the nipple.
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oscarb2b
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Posted: 02 Aug 2022 at 14:27 |
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Good to know thanks.
The seized nipple that pulled the threaded sleeve out with it, I’m thinking that will need to be fixed back in with epoxy? Or glued in somehow? And the other nipple that came out cleanly can have a new oring and maybe some PTFE around the tape too? Although not sure if that would withstand the fuel.
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oscarb2b
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Posted: 02 Aug 2022 at 18:16 |
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Spoke with Griff just now and he didn’t really comment on the O-rings behind the drain nipple, he suggested to fill the tank with water and see where the leak is coming from. Fair point really as at least I’ll be able to see all around the fuel pump area and rule that in or out.
Slightly nervous about water in and around the pump itself but Griff said as long as it doesn’t prime it will be fine
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Bladerunner919
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Posted: 03 Aug 2022 at 09:40 |
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I think the o-ring is a red herring. It is a filler between the metal nipple and the plastic tank, but not to keep fuel in/out. There is no route for fuel to be anywhere near the threads of the nipple, as it effectively screws into the 'inside' of the breather route. The only way fuel can get anywhere near the nipple is via a leak into the breathers. I was also going to suggest filing with water - you can then blow air into the breathers and see where it bubbles out.
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blacklines
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Joined: 08 Jan 2018 Location: Yorkshire Status: Offline Points: 1060 |
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Posted: 03 Aug 2022 at 12:52 |
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My head's a bit f**ked with the flu right now. So reading all this reminds me of the Patriot tv show:
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Owen
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oscarb2b
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Posted: 03 Aug 2022 at 13:28 |
This is what I’ve been thinking, unless the tank is perished on the inside somewhere near the base of the drain pipes it can only be failure of the pipes. There was a noticeable piece of ‘damage’ on the pipes halfway up the inside of the tank as shown on the picture. I will fill the tank up first without the pump, turn it upside down and then see if there are any bubbles coming up from the pipes inside the tank with some compressed air
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oscarb2b
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Posted: 03 Aug 2022 at 13:29 |
I like your thinking
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Spoonz
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Posted: 03 Aug 2022 at 19:40 |
The o ring is a mandated part depending on destination market for the fuel tank to prevent leakage from the tank in the event of failure of the internal vent pipe work . In the event that the internal pipes are sound it’s redundant as you say. If fuel is getting past them then they have failed along with something internal.
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wigginsjp
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Posted: 03 Aug 2022 at 20:45 |
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Did I just dream that you could get a hose kit to replace these in the even of internal failure once upon a time?
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oscarb2b
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Posted: 03 Aug 2022 at 21:29 |
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Interesting thanks. I want to rule out the damaged pipes first then if i find nothing, I can see what can be done at the o ring side of the system to stop the fuel getting past.
Either way I’ll need to mend the threaded sleeve that pulled out with the seized duct. I’m guessing expoxy is the answer there. I’ve got a spare tank in a different colour as a fall back plan to save the rest of the summers riding and track days. Couldn’t happen at a worse time of year!
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oscarb2b
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Posted: 03 Aug 2022 at 21:30 |
I saw on AP Workshops site replacement hoses for metal tanks so maybe that’s what you’re thinking of
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Bladerunner919 wrote: