Fuel Tank Cross-Over Revisited......New Parts!

[Shane]

Richard Oben recently brought up a post about this subject, and posted up some part numbers of some very nice rubber seals to use for the cross-over fittings in the tank. We are right at the point of doing this on a new build here, so I ordered up the parts he recommended. While we were at it, I got to thinking about an additional solution that takes care of yet another problem. Since all of the new kits are sent out with a programmable fuel gauge, all of the fuel ports and sender in the GTM Driver's side tank are completely useless. With this being the case, all of the fuel ports normally need to be plugged off, which means you have to find some way to plug them...which means searching around for something appropriate to plug them off with that will hold up to gasoline. I decided to kill a few birds with one stone, and just make an aluminum plate to replace the sender/jet-pump assembly, and put the AN fitting right in that plate. Now, no need to drill a hole in the tank at all, and no need to figure out how to plug all of the extra ports on the original assembly. The original bolts and rubber tank seal are used for the new plate, so nothing else is needed to seal this up......it seals up to the tank exactly as the OEM plate seals up!

I know there was some interest in having Richard make up a kit, and at the time, I agreed with him that it would be cheaper for everyone to just buy direct. I don't want to step on anyone's toes.......but......I suppose if there is a demand for these parts that I'm making here, I could provide them along with the seals from McMaster Carr. So, here's a break-down of the kit I could offer here. It would consist of (qty 1) of the aluminum plates as described above, to replace the "guts" of the GTM driver's side tank (with the hole for the AN fitting already cut into the plate), (qty 2) aluminum washers (made by me) that fit the AN fitting and the square-cut O-rings, (qty 2) of the square-cut o-rings, and (qty 2) of the Pressure Sealing Washer (the stainless washer with the rubber seal moulded into the washer).

The Pressure Sealing Washer would go on the AN fittings and seal the AN fitting to the tank on the GTM passenger tank, and seal the AN fitting to the aluminum plate on the GTM driver's side tank. The square-cut o-rings would then go on the inside of the tank, followed by the aluminum washers and the nut. The square cut o-rings inside the tank are not needed to seal, because the fuel is going to follow the threads to the outside of the tank anyway.....but IMO, they are needed to take care of any differences in tank thickness and provide constant pressure so that the pressure sealing washer can do it's job, and constant pressure against the nut, so the nut can not loosen up inside the tank.*The pressure sealing washers are fairly pricey little items!! My cost from McMaster Carr with shipping on these and the square cut o-rings is going to run me about $35 per kit. The Aluminum Plate is 1/8" thick as well as the 2 aluminum washers. The cost of the whole kit would be $55 plus shipping......just checked and it looks like the plate will fit into a USPS Small Flat Rate box, which I think is $5.50......so a complete kit with all the parts you need would end up being $60.50 including the shipping.

[VD2021]

Shane,

You continue to amaze me with your thorough thought process for solutions.

The way you present your solutions and your expertise are the reasons your opinion and products are greatly trusted.

I nominate Shane Vacek (VRaptor SpeedWorks, LLC) for Vendor of the Year! Keep doing what you do.

[Richard Oben]

Nice work, I do not want or need to get into the parts resale business with McMaster Carr. I did however send multiple sets to Ed in Canada.

I have not seen the new set up I assume it uses only one tank sender. In my opinion I would not do the cross over at all, as the tanks are easier to move around without the cross over. Just run the return back to the main tank and put the cross ports as leveler lines. Only downside is double filling. JMHO, Richard.

[Shane]

I never hook up the jet-pump and related plumbing......only the -12AN cross-over hose to keep the tanks level. With the programmable fuel gauge, it could care less if you have both senders hooked up or just the one in the pump (GTM passenger) tank. You just program it for ohms at empty and ohms at full and it's done. With the -12 cross-over hose, you can just fill from one side. It takes just a bit for the tanks to level out, but not too long.

[Daniel Dinverno]

One drawback I see is that the bolt pattern for the plate will possibly be different from model years. I bought a pump on ebay which came from a 2002. and the bolt pattern didn't match my tank that is 1999. I had to drill new holes that really was difficult to get right. I made a template that was slightly off and had to oval out some of the holes to get it to work and than worried that it would leak, but fortunately it worked.

[Shane]

Originally Posted by Daniel Dinverno

One drawback I see is that the bolt pattern for the plate will possibly be different from model years. I bought a pump on ebay which came from a 2002. and the bolt pattern didn't match my tank that is 1999. I had to drill new holes that really was difficult to get right. I made a template that was slightly off and had to oval out some of the holes to get it to work and than worried that it would leak, but fortunately it worked.

I guess we'll cross that bridge if the issue ever comes up. I tried to see if I can even tell when this tank was made, but I see no year stamped or marked on it.

[WHITE-BOOSTED GTM]

Shane,

Yet again you come through for me at the right time i have been waiting to do the tanks and finally i feel like i waited long enough, I do have an early 1997 tank i will be using so i can be your test mule if you like as for the aluminum plate design.

Thank again, RAY

[Daniel Dinverno]

From what I could find there are 3 different part numbers for the jet-pump sending unit assemblies. 1997-1999 2000-2003 and 2003-2012. There are Two different part numbers that exist for model year 2003.