Jeep Cherokee XJ Forum

after installing the EFI 5.0 motor into my Galaxie, i needed to install a return line into my stock steel fuel tank for the fuel injection.  the first attempt was a bulkhead fitting thru the tank with teflon washers sealing it.  this seeped continually.  due to the limitations i had going thru the very thin steel tank, tightening up this fitting correctly was umpossible and lead to it leaking fuel pretty bad.

my second attempt was to weld a steel return line into the tank.  i bent up some 3/8" steel brake line and welded a washer to it to add something to weld into the tank itself.  i followed all the recommendations and drained, washed & then aired out the tank.  waited a couple days and then attached a hose to a running car to purge the tank of gas vapor while i welded....  this would've worked fine if i'd disconnected the hose while MIG welding so that the welding gas wouldn't be blown away from the weld.  but i didn't.  i got it welded in but wasnt very happy with the results and was too afraid of blowing myself up to weld it without the hose to the exhaust purging the gas fumes.  result was a shitty weld.

third attempt was to clean up all the shitty welding and try to patch it all back together again, which worked okay, but when grinding down the welds i ended up grinding thru the tank in a couple spots because they're very thin.  time for more welding.  this time i welded it up without purging the tank with CO from a running car.  the tank had sat for a week in the sun & fumes were pretty much a non-issue.  got it welded up just fine this time, patched up the holes from grinding and as a final "just to be sure" seal, i threw on some JBWeld - WATERWELD, which is claimed to work even underwater.  i mixed it up & threw some on the inside of the tank around the return line and over the welds both inside & out.

stuff works great!  sealed up any porosity in the welds and i now have no fuel leaks.