Rusted pipes on top of fuel tank - What's the solution?

[§torm]

Hi guys,

I'm in the process of replacing the fuel lines on the rear of the SE9, to fix a small leak.

However, I've just discovered the pipes on top of the fuel tank, are very badly corroded, and seem to be the actual source of the leak.

I've read this is fairly common, but what is the recommended fix for this?

Here's a pic of the problem

[MadOnVaux!]

I dont know much about them, but looking at that, you should be able to get the whole unit off and replace it.

[Allys Cally]

I dont know much about them, but looking at that, you should be able to get the whole unit off and replace it.

this is the problem you can no longer buy the part in question

[Fraz]

only solution is find a good second hand part, then clean it up ...treat it with some rust proofer and underseal

[bigdaz1987]

mines was like that to i made one from stainless steel

[§torm]

This is the top of the fuel sender unit isn't it? Anyone know if this unit is the same on all Calibra's inc v6's and older models?

There is one on ebay off an H reg redtop. Looks like the part i need, but can't see the top end, so not sure if it exactly the same or not?

http://cgi.ebay.co.uk/Vauxhall-Calibra-Coupe-fuel-sender-unit-/250682272990

[bigdaz1987]

they are difff mate they changed at an L 94 Plate up to L 94 has a external fuel pump then M 95 on has a internal fuel pump so that one wouldnt fit

[v6 steve]

mines was like that to i made one from stainless steel

why dont you make some more and sell them in the club to members i would have 2 and while your at it GET ON WITH MA BUMPER PANEL

[GreyDJ]

Although they are in that bad state do they leak? (the pipe under the hose will be OK)

If not, I would scrape off as much loose rust from the pipes and baseplate as possible, treat it with Kurust or similar and encapsulate them in something like JB Weld (epoxy metal), taking good care where they join the baseplate. You will end up with a big 'metal' lump that should never leak even if the pipes disappear. You might have to build a metal dam around the pipes as JB Weld self levels.

Treat it as a temporary solution but it could last a long time.

[MadOnVaux!]

Are these the same for any other Vauxhalls?...just there is a few good ones on ebay.

For example this one for a Vectra...

http://cgi.ebay.co.uk/VAUXHALL-VECTRA-9 ... arParts_SM

The pipe's look at slightly different angles, but the plug looks the same.

[§torm]

Right i've knuckled down and done a repair job on this, and glad i did in the end, as it really wasn't that bad once you get on with it.

For anyone else that comes across the thread this was what i did.

1) Use a dremmel tool or similar, (I bought one off ebay for £25 posted) and wire brush attachment to remove all the rust, including as much as possible from the pitted areas.
2) Soak overnight in vinegar to lift off any remaining rust in hard to reach and pitted areas. Reading on the net, you can also use coke as it contains phosphoric acid which is an ingredient for rust removal products. Although vinegar worked well for me.
3) Use Chemical/Liquid metal compound (you can buy this in Halfords for a few quid) to fill any holes and layer up on thin or weak areas. Poke a straw through the pipe to ensure a clear passage, in the event you have to patch up any sizeable holes in the pipes themselves. Allow to dry.
4) Sand down repaired areas to leave a smooth finish.
5) Paint over with 2 coats of Hammerite No 1 Rust Beater (comes in Brown and Beige). You apply this directly to the affected metal, and it also acts as a primer and undercoat.
6) Paint over with 2 coats of Silver Hammerite Paint to give a nice finish and added protection.
7) Refit part to tank and admire your handiwork.

In my case i also replaced my fuel lines (8mm kunifer pipe) and rubber hoses as these were corroded and perished as well. I also replaced the fiddly crimp clips with screw tight hose clips (size 13) which are much easier to fit and remove.

Here's the before and after picures

BEFORE



AFTER

[Allys Cally]

looks like new, i'll just send mine to you to get done then

[MadOnVaux!]

Thats bloody excellent work mate well done.....full credit to you too for having a bash at it

[§torm]

Cheers guys.

Once i removed the surface rust, it didn't look nearly so bad, and there was plenty of good metal underneath. The underside of the plate was in very good nick, and was virtually unmarked. I still gave it 2 coats of hammerite though for good measure.

Once the rust was removed, I also found the source of the leak as 2 very small holes, 1 in the pipe, and 1 in the flat metal plate, which were both filled with the metal compound.

Hopefully i've done a thorough enough job on it to keep the rust at bay, and it'll be good for another few years to come!

[lammy]

excellent work..and a good guide as it appears to be coming a popular problem!..i'm sure mine won't be far off?