Modifying a fuel sending unit for a return line...

Posted by D-train On 2015/8/3 20:31:37

Hi,

While I am not doing this to my Packard, it is a modification and I figured to ask the knowledge base here for help.

I have a fuel sending unit (side tank mounted) that already has a single (3/8) outlet. I need to add a second line for a return. I'm working with a new unit (either Kanter or Classic Car Auto Parts) that has zinc coated steel. I planned on drilling the hole and then try to dimple it so as to give the solder more surface area. (the original line was soldered) Or should I just TIG weld it? (I have a TIG welder but have yet to get any practice in onfirst) The original piece had a "collar" around the line. It looked like the plate was stamped that way. Did the factory solder these to save on $ ?

I would think that I could TIG it, but maybe I am missing something that is obvious to the knowledgeable. Otherwise is there a specific solder to use?

Thanks,

Mark