Mercedes Mullins
Installing a fuel tank bulkhead fitting can be a challenging task, especially when access to the inside of the tank is limited. The process may involve drilling holes in the tank and securing fittings, while also ensuring that potential leaks are prevented. One method suggests installing the fitting from the inside out, allowing for easier tightening of the nut on the outside. This requires an opening at the top of the tank large enough to pass the bulkhead through. Another approach involves using specific tools such as needle-nose pliers and wrenches to tighten the nut and secure the fitting. In some cases, trimming the flange of the bulkhead fitting may be necessary to ensure a proper fit. The use of gaskets, sealants, and washers is also recommended to prevent leaks and create a secure seal.
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What You'll Learn
Drilling holes for the bulkhead
When drilling the holes, it is essential to use the appropriate tools and techniques. A hole saw or a drill can be used, depending on the material of the fuel tank and the size of the hole. If the tank is made of plastic, drilling and tapping may be required. It is also crucial to consider the size and placement of the holes to ensure they do not compromise the structural integrity of the tank.
After drilling the holes, it is important to prepare the area for mounting the bulkhead fittings. This may involve cleaning and deburring the holes to ensure a smooth and secure fit. Additionally, applying a sealant or using washers can help create a tight seal and prevent leaks. It is recommended to use washers on both sides of the bulkhead fittings, especially when working with plastic fuel tanks.
In some cases, trimming the flange of the bulkhead fitting may be necessary to ensure a proper fit. This can be done using a grinder, but it is important not to remove more than 1/8" of material. When tightening the bulkhead fittings, it is essential to follow the manufacturer's instructions and consider the use of gaskets, sealants, or both. However, it is crucial not to use a gasket and a sealant simultaneously, as this can compromise the effectiveness of the seal.
Overall, drilling holes for the bulkhead requires careful planning, precise execution, and the use of appropriate tools and techniques to ensure a secure and leak-proof installation.
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Using epoxy to prevent leaks
When installing a fuel tank bulkhead, using epoxy is a recommended way to prevent leaks. A two-part epoxy putty, such as Permatex Fuel Tank Repair, can be used to seal the bulkhead fittings and prevent leaks. It is important to prepare the surface properly before applying the epoxy, ensuring that it is clean and dry. The two-part epoxy is mixed until the colours become uniform, indicating that it is thoroughly mixed. This epoxy can also be used to repair small leaks in steel diesel tanks.
For those seeking a more permanent solution, Devcon epoxy is a strong option. This product can be used to seal threads on fuel tanks and has been reported to successfully stop leaks. It is important to note that some epoxies may have trouble hardening if they come into direct contact with gasoline, so it is recommended to allow for curing time before using the tank.
Another option is to use a combination of teflon washers and Blue Locktite, which can also be used on fuel, nitrous, and brake line fittings. This method provides the assurance of a strong seal, and the Blue Locktite can be used in conjunction with epoxy for added security.
For those working with plastic fuel tanks, it is recommended to use a fuel-resistant epoxy, as some standard epoxies may not hold up to the presence of gasoline. A product such as the Moroso 2-part epoxy has been reported to work well in this application. When working with plastic tanks, it is also important to consider the use of bulkhead fittings designed for plastic, such as Earl's -10 bulkhead fittings with teflon washers on both sides.
By following these recommendations and using epoxy to seal bulkhead fittings, it is possible to prevent leaks and ensure the proper functioning of your fuel tank.
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Choosing the right fitting
Type of Fuel Tank
Consider the type of fuel tank you have, whether it is made of plastic, steel, or another material. Some fittings are specifically designed for certain types of tanks, such as plastic fuel cells with nylon washers on both ends of the fitting. For steel tanks, welding or brazing on a used gasoline tank is an option, but it is recommended to consult a professional for this method.
Tank Wall Thickness
Ensure that the bulkhead fitting is compatible with the thickness of your fuel tank or cell wall. Fittings are designed for specific wall thicknesses, so it is important to check the product specifications before making a purchase.
Size and Diameter
Sizing the bulkhead fitting correctly is essential. Measure the diameter of the fuel line or hose that will be connected to the bulkhead fitting, and choose a fitting with matching threads and an inner diameter that creates a snug fit. This helps prevent leaks and ensures the proper functioning of your fuel system.
Cost and Availability
Bulkhead fittings vary in price depending on factors such as size, material, and brand. Basic bulkhead fittings typically start at around $10 to $20 for smaller sizes, while larger sizes can cost $50 or more. High-performance or specialty fittings for racing or performance applications can range from $30 to $100 or more per fitting. Consider your budget and the total cost based on the number of fittings required for your setup.
Sealing and Leak Prevention
To prevent leaks, consider using epoxy around the fittings for extra assurance. Additionally, securing the line coming out of the bulkhead fitting close to the tank can help keep any flex off the fitting, reducing the potential for leaks. Some fittings may also come with features like washers or seals specifically designed to prevent leaks.
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Using a gasket or sealant
When installing a fuel tank bulkhead, one of the key considerations is whether to use a gasket or sealant. This decision will depend on the specific application and the materials being used.
If you choose to use a gasket, it is important to ensure that the surface between the tank and the bulkhead is smooth and free of any debris or imperfections. The gasket should be placed between the tank and the bulkhead, creating a tight seal that prevents leaks. In some cases, the gasket may be sufficient to hold the bulkhead in place while you tighten it. However, if the gasket does not provide enough support, you can use a wrench to hold the "tail" of the bulkhead fittings while tightening the nut. It is important to note that this method may damage the threads on the bulkhead fitting, so it is recommended to wrap the threads with cardboard or a rag to minimize damage.
Alternatively, you may choose to use a sealant instead of a gasket. Common sealants used in fuel tank installations include silicone or urethane. If you are using a sealant, it is important to follow the manufacturer's instructions for proper application and curing time. Unlike gaskets, sealants can be messy and require more time to cure. Additionally, it is crucial never to use a gasket and a sealant simultaneously, as this will cause the gasket to be pushed out.
In some cases, you may not have access to the inside of the tank, which can make installing the bulkhead fitting more challenging. If you only have access to the outside of the tank, it is recommended to install the fitting from the inside out, so the nut is on the outside and can be easily tightened. This method requires an opening at the top of the tank large enough to pass the bulkhead through. For smaller tanks, such as 30 or 55-gallon drums, the opening may only accommodate a 1/2" or 3/4" bulkhead. By running a stiff wire from the hole at the top to the hole on the side of the tank, you can thread the bulkhead onto this wire, with the nut end first, and then tighten the nut from the outside.
Overall, the decision to use a gasket or sealant depends on the specific requirements of your fuel tank bulkhead installation. Both methods can effectively create a seal and prevent leaks, but it is important to consider the advantages and limitations of each approach to determine the most suitable solution for your application.
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Securing the line after fitting
First, it is important to securely bracket the line coming out of the bulkhead as close as possible to the tank. This will help reduce any flex on the bulkhead fitting, minimising the risk of leaks. You can use epoxy around the fittings for added security and peace of mind.
When securing the line, it is recommended to use appropriate fittings, such as 3/8"NPT to -8/-6 fittings, along with washers and nuts to ensure a tight seal. Drilling and tapping the tank material, whether it be plastic or metal, will help create a secure connection for the fittings.
In terms of sealing, aircraft fuel tank sealant or similar products can be applied to the fittings before screwing them in. This will create a strong barrier against leaks. Additionally, using a gasket can be an effective way to hold the bulkhead fitting in place. However, if you prefer to not use a gasket, you can opt for silicone or urethane, but be aware that this method can be messy. It is important to note that you should never use a gasket and a sealant simultaneously, as the gasket will be compromised.
For added assurance, you may want to consider using epoxy on the outside of the fittings, further reducing the chances of leaks. Taking your time during installation and paying attention to detail will help ensure a secure fuel tank bulkhead installation.
Lastly, depending on the specific setup of your vehicle, you may need to modify the bulkhead fitting to ensure it fits properly. For example, if the opening at the top of the barrel is almost large enough, you can use a grinder to carefully trim down the flange of the bulkhead fitting by a maximum of 1/8" around. This will help you achieve a snug fit without compromising the integrity of the fitting.
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Frequently asked questions
If you only have access to the outside of the tank, it is better to put the fitting in from the inside facing out so the nut is on the outside, making it easier to tighten. You will need an opening at the top of the tank large enough to pass the bulkhead through. For most 30 or 55-gallon drums, you can install a 1/2" or 3/4" bulkhead. Run a stiff wire from the hole at the top to the hole you drilled in the side of the tank, then thread the bulkhead onto this wire, nut-end first.
You will need a drill to make the hole for the bulkhead fitting. You will also need a pair of needle-nose pliers to pull the wire through the hole, and a wrench to tighten the nut. If you need to trim the flange of the bulkhead fitting, you will need a grinder.
To prevent leaks, you can use a gasket or a sealant like silicone or urethane. However, you should never use a gasket and a sealant together. You can also use epoxy around the fittings for extra assurance.
