Mercedes Mullins
Adding brass fittings to a plastic fuel tank can be a challenging task due to the unique properties of plastic. Most adhesives or epoxies will not bond with the plastic material used in fuel tanks, and creating threads in the tank by drilling or tapping may not be feasible due to the risk of stripping. One possible solution is to use a fuel valve with an o-ring seal and screws that can be attached to partially drilled holes in the tank. Another method involves spinning a plastic fitting at high speed and pressing it into the tank, allowing friction to melt the plastic and create a seal. This, however, requires specialized equipment and is not a typical DIY procedure. To ensure a secure connection, it is recommended to use Teflon tape for sealing, and a bulkhead fitting that clamps to the wall of the tank.
Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Materials | Brass, Plastic, Teflon Tape, Epoxy, Rubber Washers, Steel |
| Tools | Drill, Hole Saw, NPT Tap |
| Techniques | Drilling, Tapping, Clamping, Brazing, Spinning and Pressing Fittings |
| Considerations | Safety, Sealant Compatibility, Structural Integrity, Expansion and Contraction, Fire Hazards |
| Suggested Suppliers | JEGS, SUMMIT RACING, EARLS, WeatherHead, ACE Hardware |
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What You'll Learn
Use a sealant like Teflon tape to prevent leaks
When adding brass fittings to a plastic fuel tank, it is important to use a sealant to prevent leaks. One option is to use Teflon tape, which is a type of thread sealant that can create a tight seal and prevent leaks. Teflon tape is a good choice because it is not affected by gas and will not cause any harm. It is also flexible and can conform to the shape of the fitting, helping to create a strong seal.
To use Teflon tape effectively, start by cleaning the area where the brass fitting will be attached to the plastic fuel tank. Make sure the surface is free of any dirt, grease, or debris, as this will help the tape adhere better. Once the area is clean, cut a small piece of Teflon tape and wrap it around the threads of the brass fitting in a clockwise direction. Make sure the tape is tight and secure, with no gaps or overlaps.
After the Teflon tape has been applied, you can screw the brass fitting into the plastic fuel tank. Use a wrench or other tool to tighten the fitting, but be careful not to overtighten it, as this can damage the plastic. Once the fitting is secure, check for any leaks by filling the tank with water or another liquid and inspecting for drips or wet spots.
In addition to Teflon tape, you can also use other sealants like pipe dope or epoxy. However, it's important to choose a sealant that is compatible with fuel and will not break down over time. Some sealants may not be effective with certain types of plastic, so it's important to test a small area first or consult with a professional.
By following these steps and using a sealant like Teflon tape, you can effectively prevent leaks when adding brass fittings to a plastic fuel tank. It is important to take your time and ensure that all connections are secure and sealed properly to avoid any potential hazards.
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Choose a fitting with nylon washers for both ends
When adding brass fittings to a plastic fuel tank, it is important to choose the right type of fitting. One recommended option is to use a fitting with nylon washers on both ends. This type of fitting, also known as a fuel cell fitting, is commonly used for plastic fuel tanks and can provide a secure and reliable connection.
Nylon washers are designed to create a tight seal between the fitting and the plastic fuel tank, helping to prevent leaks. They are made from a durable and flexible material that can withstand the expansion and contraction of the tank without compromising the seal. This is especially important for fuel tanks, as leaks can pose a safety hazard.
When selecting a fitting with nylon washers, it is important to ensure that the washers are the correct size and compatible with the fitting and the plastic fuel tank. It is also crucial to consider the location of the fitting on the tank. While some sources suggest installing fittings at the bottom of the tank, this may not be advisable due to the potential for leaks and the safety risks associated with fuel expansion and contraction.
Instead, it may be more suitable to install the fitting at the top of the tank, ensuring that it is securely clamped and sealed. This can be achieved by using Teflon tape or pipe dope to seal the connection, in addition to the nylon washers. By taking these precautions and choosing the right fitting with nylon washers, you can help ensure a safe and effective connection for your plastic fuel tank.
Overall, choosing a fitting with nylon washers for both ends is a recommended approach when adding brass fittings to a plastic fuel tank. This type of fitting provides a secure and leak-resistant connection, which is essential for fuel systems. By selecting the appropriate washers and considering the location of the fitting, you can help ensure the safety and reliability of your fuel tank setup.
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Drill holes in the tank for the fittings
Drilling holes in a plastic fuel tank is a delicate process. It is important to take the necessary precautions to avoid any leaks or damage to the tank. Before drilling, it is recommended to use a hole saw to create a precise and clean cut. The hole saw should be of an appropriate size, matching the diameter of the fittings you plan to install. Mark the desired location of the fittings on the tank and slowly drill the holes, taking care not to apply excessive force that could damage the plastic.
After drilling, it is crucial to deburr the holes to remove any sharp edges or debris that may have been created during the drilling process. This can be done using a deburring tool or a file. Once the holes are smooth and free of any burrs, it is time to prepare the fittings for installation.
It is recommended to use brass fittings with Teflon tape or nylon washers to create a secure seal. Wrap the tape around the threads of the fittings or use washers on both ends to ensure a tight fit. Carefully insert the fittings into the drilled holes, making sure they are properly aligned and seated.
To ensure a leak-proof connection, you may consider using a sealant specifically designed for fuel tank applications. Aircraft fuel tank sealant can be applied to the fittings before screwing them into the tank. This will create a strong bond and prevent any fuel leaks. Allow the sealant to cure according to the manufacturer's instructions before filling the tank with fuel.
Additionally, you can use epoxy on the outside of the fittings for added security. By following these steps and taking your time, you can successfully drill holes in a plastic fuel tank and install brass fittings securely and safely.
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Use brass fittings for safety
Brass fittings are a popular choice for specific applications due to their safety and reliability. Here are some reasons why using brass fittings is a safe option:
Corrosion Resistance
Brass is highly resistant to corrosion, which makes it a suitable material for fittings in various environments. This property is especially important in saltwater applications, where other metals may corrode more rapidly. For example, in boating, brass fittings are often used above the waterline and in dry places to avoid corrosion.
Tight Seals
Brass fittings can form tight seals, reducing the chances of leakage. This characteristic is crucial for maintaining the integrity of systems where leaks could pose safety hazards, such as gas pipelines.
Workability and Affordability
Brass is a soft metal that is easy to work with and shape into complex curved designs. Its softness also reduces the risk of cracking during the forming process. Additionally, brass is typically affordable and widely available, making it a cost-effective option for many applications.
Electrical Bonding
In certain situations, such as in boats, it is important to electrically bond brass fittings to the anodes. This bonding ensures a secure connection and helps protect the fittings from degradation, provided there is less than one ohm of resistance between the fittings and the boat's hull anode.
However, it is important to note that brass has some limitations. For instance, in winemaking, brass is avoided due to its tendency to leach into wine, affecting its quality. Additionally, brass is softer than some other metals, making it more prone to pitting, scratching, and thread loss over time, which can lead to increased maintenance needs.
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Avoid rubber hoses for the pressure line
When adding brass fittings to a plastic fuel tank, it is important to consider the type of hose used for the pressure line. While rubber hoses may seem like a convenient option, there are several reasons why they should be avoided for the pressure line in a fuel system.
Firstly, rubber hoses are susceptible to degradation over time. The increasing use of ethanol in pump fuel can shorten the lifespan of rubber hoses as ethanol is chemically aggressive and can attack the rubber compounds. This can lead to leaks and potential safety hazards. Solid lines and fittings are generally more durable and less likely to fail over time. While solid lines may not offer the same flexibility as rubber hoses, it is possible to incorporate a short rubber line near the throttle body to provide some flexibility without compromising safety.
Secondly, rubber hoses can be more prone to punctures and damage from road hazards. A puncture in the rubber hose can lead to fuel leakage, which is a safety concern and can cause environmental damage. Using a solid line, such as steel or stainless steel braided lines, provides better protection against cuts and abrasion. This reduces the risk of leaks and improves the overall safety of the fuel system.
Additionally, rubber hoses may not be compatible with certain fuel types and additives. Some states have introduced oxygenated fuel blends during the summer months, and these blends can degrade rubber hoses more quickly. It is important to consider the type of fuel and any additives that may be present when selecting the appropriate hose material.
Furthermore, rubber hoses may not provide the necessary pressure rating for the fuel system. Solid lines, such as stainless steel braided lines, often have higher pressure ratings and are better suited for high-pressure applications, such as fuel injection systems.
Finally, while rubber hoses can be cost-effective and flexible, they may not be suitable for use inside the car. Rubber hoses can allow vapours and fumes to escape, creating an unpleasant environment in the cockpit. Solid lines or hoses with proper vapour barriers are more suitable for inside the car to prevent fumes from escaping.
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Frequently asked questions
It is recommended to use brass fittings with a plastic fuel tank, as plastic fittings are unsafe. To install the brass fittings, you can use a drill to create holes in the tank and then screw in the fittings. It is important to use a sealant, such as Teflon tape, to prevent leaks.
Teflon tape is a recommended sealant as it is not affected by gas. Aircraft fuel tank sealant is another option that has been used successfully.
It is not recommended to put fittings at the bottom of a plastic tank due to expansion and contraction, which can cause leaks. Coast Guard regulations also prohibit fittings on marine tanks anywhere but on top.
Steel line fittings are considered the safest option. However, rubber fuel lines are also commonly used and can be made safe with proper installation and maintenance.
Yes, it is important to be cautious when drilling holes in the plastic fuel tank to avoid any damage. Additionally, ensure that the fittings are tight and secure to prevent leaks.
