Fuel Tank Cross Over Pipe - My Fix

512dude · Last edited by 512dude on Tue Aug 18, 2009 12:00 pm; edited 6 times in total

Tired of the nylon fittings busting on the cross over tube (this is the 2nd time for me) and the fact that VW has discontinued them I decided to make my own fittings.

This took me a few hours on a lathe and got me what I needed.

Very Happy

I really was ready to just fabricate my own fuel tank and eliminate the whole cross-over equlization and venting non-sense but that was going to take a bit more time. I'd really like to thermo form a poly-tank but would have to price that out as well as the tooling. Maybe if I had a whole lot of youse guys commit to a bigger lighter poly tank we could make it a tank co-op effort and split the costs. Wink

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ProvoCyclist · Posted: Tue Jul 21, 2009 5:15 pm Post subject:

Sir, this is awesome! Welcome to the Samba!
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Current: 1986 Tintop GL 2wd, stock 2.1L, manual trans, Savanna Beige Metallic LH1V.
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RCB · Posted: Tue Jul 21, 2009 5:22 pm Post subject:

I must be a french fry shy of a Happy Meal but I dont see a few hours on a lathe.
I see a 90' brass angle piece and another brass piece sticking out of it.

Looks as if a drill bit could have accomplished the same thing.
Im interested so please explain.

James 93SLC · Posted: Tue Jul 21, 2009 5:38 pm Post subject:

Am I the only one not seeing the pictures ??

edit: seeing them now, but only after switching rendering in Firefox from IE back to Firefox. Weird Confused

VisPacem · Posted: Tue Jul 21, 2009 11:19 pm Post subject:

randywebb

deprivation · Posted: Wed Jul 22, 2009 8:01 am Post subject:

Maybe re-do the post. I'm not seeing the pictures, either.
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shadetreemech · Posted: Wed Jul 22, 2009 8:10 am Post subject:

512dude · Posted: Wed Jul 22, 2009 10:33 am Post subject:

Let me explain...

You are correct, the part you see is an off the shelf fitting but I did need to modify it by taking the barbs off the neck from one side so that it sealed well against the grommet. My tests showed that with the barbs in place it didn't retain itself as well and I figured I might as well do it right the first time. However. since I am an amateur machinist I had to figure out how to hold that fitting in the lathe so I could turn the neck down. That part took me the longest until I discovered a 4 jaw chuck hiding in the cabinet below the machine. Very Happy

I turned down the two fittings and then drilled a hole 45 degrees to the corner of the elbow. I then found a 1/4" barbed fitting that also needed to be turned down to fit inside the hole I drilled.

Last step was to braze the two parts together to get a good seal.

dbo550 · Posted: Wed Jul 22, 2009 10:40 am Post subject:

I don't have access to a lathe so how much would you sell a set of those for?
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randiego · Posted: Wed Jul 22, 2009 10:54 am Post subject:

512dude · Posted: Wed Jul 22, 2009 11:06 am Post subject:

Busted fittings result in gasoline leaking on to the top of the tank - especially when full - and a strong odor of fuel after filling the tank. If you jack up the front end of your vehicle you can reach thru the wheel well and check the fuel cross over line fittings to see if they are cracked. I can just weasel my arm thru the wheel well when my van is not jacked-up but it is tricky. I was doing this occasionally at the gas pump after filling up to check for leaks.

Re: costs for making a tube....I'm checking what it would cost in larger quantities with options to supply folks with them Wink

tencentlife · Posted: Wed Jul 22, 2009 8:16 pm Post subject:

Excellent solution. Well done.
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westylife · Posted: Thu Jul 30, 2009 11:24 am Post subject:

Nice Job! You better get a patent for this quick before someone steals your idea Shocked

I can think of one person on here who is probably trying this out right now (its not me). Mail yourself a copy of your drawings and don’t ever open it, save that for a judge. I'm not sure how far you want to go with this but it’s just an idea.

And you got an EXCELLENT from tencent so you know you are golden Smile

I would be interested in this as well.

Cheers,
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RadioRental · Posted: Thu Jul 30, 2009 12:00 pm Post subject:

This is awesome work!

Very briefly.. on the 'patent' idea, I wouldnt rush out just yet. While not exactly quite like the design above, and not suitable for our petrol tanks I found this on the first search

"3/8" OD x 1/4" ID Reducing Tube Tee with 1/4" x 1 /8" Side Barb sized for the smaller Primer Line (as shown in picture with tubes attached). Price = $ 3.44 each"
http://www.lakeaviation.ca/accessories.html?CategoryID=102

I'm sure with a little more digging one could find a better match for our requirements.

I'm not trying to piss on anyone's parade, this is a great custom solution (especially machining off the upper barb)

insyncro · Posted: Tue Aug 18, 2009 6:03 am Post subject:

I would highly recommend getting intouch with VanCafe.
They are looking for people such as yourself and great Vanagon specific fixes to sell for you.
They could sell many I'm sure.
Nice job.
Good price.

dylan

Mr. Electric Wizard · Posted: Tue Aug 18, 2009 6:37 am Post subject:

Right on!
I knew somebody would step up...
Cool

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newt909 · Samba Member Joined: March 30, 2009 Posts: 39 Location: MA

not to burst bubbles, and I think copper is so much prettier than aluminum but van-cafe has a set-up already.

http://www.van-cafe.com/home/van_1249817945240/page_495_971/fuel_tank_cross_over_pipe.html

goffoz · Samba Member Joined: May 09, 2007 Posts: 1486

I've always wondered why VW used 2 expansion tanks in the system?
...with the cross over tube..wouldn't just one be enough? Confused

MarkWard · Posted: Tue Aug 18, 2009 8:36 am Post subject:

The top of the fuel tank has a low spot down the center to accomodate I believe the heater tube on an air cooled vanagon and the shift linkage. This design left the fuel tank with two identical high spots. The engineers probably felt it necessary to vent both sides independently which included the two tanks. The cross over tube was neccessary to equalize the atmoshpere on both sides of the tank on fill up. Just a guess.


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