Urgent Help! - Leaking fuel like crazy...

[Javamoose]

So, I finished re-lining my tank and installing new fuel lines, fuel filter and dumping the vac petcock for a manual one.

Just added half a gallon of gas to check for leaks and boy do I have a big one.  The fuel sender is leaking like a sieve.  The nut seems pretty well on there, but it's still leaking.  How tight do you have to crank that plastic nut down?  It's only sealed by the gasket compressing against the top of the threaded fitting, right?  Anyone have any tips/experience/anything to help? 

[Speeddog]

Pull the ring nut off and see if you've farked the gasket or there's debris or a burr preventing it from sealing.

[The Bearded Duc]

Any time I've worked on my tank it's taken a little bit of elbow grease to tighten down that fuel sender properly.

Although I've never had any problems, some people warn about messing up that gasket/washer. If yours is tweaked that may be whats causing the leak.

Drain the fuel, disconnect the sender and check the washer. When you screw the sender back on be mindful that the threads are lined up then tighten that thing down. When you think its tight enough give it just a bit more.

[Javamoose]

Ok, sadly the sun is now down - no garage - so i'll just have to let the gas evaporate for tonight.

I will try both suggestions first thing in the morning.  I only went as tight as I could get it by hand, literally by hand since I don't have a wrench that big.  I figured with a plastic nut, how tight could it go.    Know what size that nut is?  I'm going to go out and buy a big wrench...

[The Bearded Duc]

Just pick up one of these...



They're available at any hardware or auto parts store. Just make sure you get a pair that opens to at least 2 inches.

[koko64]

+1.
And order an alloy nut from Cal Cycleworks or whoever. I'm using an alloy nut from an old original sender that failed on my new sender unit. The plastic ones have been known to warp or crack.

[Javamoose]

Duc750 - Exactly what I was thinking. 

+1.
And order an alloy nut from Cal Cycleworks or whoever. I'm using an alloy nut from an old original sender that failed on my new sender unit. The plastic ones have been known to warp or crack.

Good idea, I'll order one as a back up.  Surprisingly, the original one is in great shape...

[Javamoose]

Yay!!  It was WAY too loose.  Tightened it up and all is golden. 

New exhaust is farkin' loud!  She's backfiring like a mofo, but it sat for a year, so...kinda to be expected.  But no gas leaks! 

[The Bearded Duc]

Awesome man, glad the problem is fixed!