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76solder.jpg | Hits: 13483 | Posted on: 4/17/11 | View original size (2.22 MB)

To temporarily (or indefinitely) run any '90-96 dual-tank truck on 1 tank, it's necessary to plug both unused tank lines & the vapor line.

I used the old rear tank plate as a blockoff for the fuel lines because it seals to the fuel lines without damaging or modifying them. After removing the plate/pump assembly from the tank & lines, and then removing the level sender & FDM from the plate, I heated both tubes to dry the old gas out & cook the varnish into ash. Then I used a brass bore brush to clean the tubes inside, and rinsed them with carb cleaner. Then I flipped it and melted rosin-core electrical solder into them so it pooled in the first bend, blocked the ends with a metal putty knife, and flipped it back so the solder hardened into a plug at the bottom end. This is with the truck running, so it works. Use a bolt or vacuum cap to plug the vapor line.

To UNdo it & use this pump plate again, just disconnect the lines, dump ALL the gas out of the tubes, heat the tubes to melt the solder, and let it run out. DO NOT put a torch to it while the fuel lines are connected, OR anywhere near the open fuel lines or tanks! Then press the plate into a working FDM reservoir, hang the level sender, and connect the wiring before re-installing the assembly into a tank.

For more info, read these captions:

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