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After much trepidation on my 1977 resto mod, I drilled the 1/2 inch diameter hole in the plate the filler tuba and sender are attached to. Some previous owner had kindly welded the original fuel pump return closed. It is a tight fit, but seems to be ok. The only problem is that the gasket under the adapter fitting has deformed and squeezed out from under the flange. It shouldn't leak fuel since it is above the full level in the tank and it is a return fitting so fuel would come out the end about 1 inch below the fitting flange itself.
I am thinking I might use silicon sealer and put a small bead around the fitting, this should stop any vapors. Now that is done, I can lift the car up and continue with the fuel injection conversion and fix a few other things before the spring.
Without a picture I'm not familiar with "late model" Vettes. I recently had a similar issue and located some supposedly fuel/oil resistant clear sealer at AutoZone. I sanded and cleaned the area with acetone, then applied the sealer. on an area I welded on the bottom of the tank. Even though I pressure-tested the tank before applying the sealer, I didn't want to take any chanceson future leaks at the welded area.
So far...no leaks or seepage from the sealer with 10 gallons of gasoline in the tank. It has been nearly a month now.
Last edited by doorgunner; Feb 6, 2021 at 05:34 PM.