Help with fuel tank crossover issue!
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Joined: Jul 2012
Posts: 54
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From: Chicago
Help with fuel tank crossover issue!
Greetings to HD Forum-ites,
My father always told me, "The dumbest question is the one that is not asked." so here goes:
The metal elbow on my fuel tank (03 Ultra EFI) that connects the crossover line broke off and dumped about 3 gallons of fuel all over the garage. After cleaning up the mess I had a chance to inspect the damage. I see that the elbow was brazed on, but I just had the bike painted and don't want to ruin the paint or dismantle the tank. A friend (HD mechanic) said there's enough material in that area to tap threads and install an aircraft-type fitting. What do you guys think? Any help would be appreciated. Thanks!!
My father always told me, "The dumbest question is the one that is not asked." so here goes:
The metal elbow on my fuel tank (03 Ultra EFI) that connects the crossover line broke off and dumped about 3 gallons of fuel all over the garage. After cleaning up the mess I had a chance to inspect the damage. I see that the elbow was brazed on, but I just had the bike painted and don't want to ruin the paint or dismantle the tank. A friend (HD mechanic) said there's enough material in that area to tap threads and install an aircraft-type fitting. What do you guys think? Any help would be appreciated. Thanks!!
Cruiser
Joined: Dec 2007
Posts: 234
Likes: 1
From: Knoxville TN
there is not enough metal there to tap...that's why it was brazed in from the factory. Its pretty much repair it that way or find a used tank on ebay. Any makeshift repair such as tapping it will only lead to a breakdown some where which could lead to a fire as well. The easy fix isn't usually the best fix. If you're comfortable straddling a potential fire bomb...go for it
Cruiser
Joined: Mar 2012
Posts: 157
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From: North Shore of Minnesota
There are options. The tank is not under pressure so most compression or flare seal type fittings will work. I will do a quick search and get back to you. is there a nice clean concentric hole or can you drill one?
Outstanding HDF Member
Joined: Oct 2009
Posts: 2,488
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From: Maryland near DC
there are ways to fix it...you will need to drill the hole nice and round and flush..then you can get a fitting that goes in from the inside of the tank and sticks out of the hole you drilled and a rubber washer and nut go on the outside....do a search you should be able to find a fix....
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Joined: Nov 2005
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From: KMHT KFMY
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Joined: Jul 2012
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From: Chicago
I can definitely clean it up to make way for good threads.
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Joined: Jul 2012
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From: Chicago
Thanks for all the replies! Revelator, I understand what you're saying - I've straddled worse - but I will definitely test it before hitting the road. The bulkhead fitting seems like the way to go.
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