Okay, I found a nice brass barbed fitting that screwed nicely into the pickup line, but I still need to work out the return. You guys have given be several good suggestions, but I don't see that I'll be able to do anything very elegant just yet.

I crawled around under the car hooking up the new fuel injection hose, and the new fuel filter, a couple of ideas came to me. I'd like an opinion on these before I pull the tank for installation.

1) The crazy idea.
Pull the drain plug, install a brass NPT elbow and hose barb. Use this as the pickup and route the return into the original pickup. Advantage being that the tank can stay in place, and no drilling or bung installation will be needed.

Okay. Obviously there would be a risk of road debris hitting the setup - especially if the rear of the wagon bottoms out. Plus I imagine that the weight/pressure of the fuel from the tank might put too much pressure on the intake side of the pump. A damaged elbow could drain all the fuel and create a fire hazard on the road. Fun stuff. my assessment if that it would not a good idea for more than a test...

2) The more reasonable idea.
Access to the tank body for bung installation is going to be problematic. Trying to snake a socket extension and nut through the sender hole sounds like a small nightmare in dropped parts and tank shaking. Plus there's the whole drilling the metal with the risk of residual gas vapors - even a year after the car was last started.

So... looking around the tank for other places to put a return hose barb, I hit upon the filler neck. On the wagon it's on the left in a large open area and I'm pretty sure I can mount a bung in that neck without loosing the fittings down the neck too many times.

Question is... would that work? It would be simple to run a hose around to a barb in the filler neck, but I worry that it coming in "high" might cause fuel to slosh up and make out the small venting setup in the neck...

Here's the area I thinking about...


Where can I buy a bung fitting kit?