I broke my fuel return at sender unit

[kevinkay]

HELP!

Any way I can "jimmy" this back together until I get a new sender unit?

Its the return side (behind driver without pump).
Can I drive the car with the return line just plugged off?

Was going to try epoxy??

[cn90]

- You need the return line, otherwise pressure building up significantly!

- My suggestions:

1. Get a dremel and cut the tabs on both sides of the remaining tub. Now you have a short stub, find a rubber plug and plug it off.

2. Get an appropriate barb fitting and rubber washers and nut, drill a new hole and install the barb fitting, then the return hose goes to the barb fitting.

[kevinkay]

AH....GREAT IDEA!

But doesn't the return line have to go back though that same hole - it connects to 2 tubes underneath (part of the siphon system??).

Thinking maybe I can tap the plastic hole and screw in the barb fitting your showing me.

A walk to the hardware store, thanks for the great idea!

THANK YOU!!

[cn90]

Or drill the existing hole to fit the barb fitting.
Sand the surface smooth to ensure a good seal.
Make sure you get rid of the debris created by drilling.

[kevinkay]

YES, your right!
THANK YOU FOR THIS IDEA!
Did'nt get to the hardware store so I dont have a barb yet.
Hopefully I can find a barb tomorrow.
I have about an inch of broken plastic tubing left, its on an angle. I think I will first try to tap it to whatever thread barb I can find, and If I am not happy with the fit then I will Dremel down the the broken plastic flat, then drill the hole to the size I need, brass nut and maybe "O ring" on top side of barb.
I pulled the sender unit so I wont contaminate the tank.


I would not have thought of this on my own - THANK YOU

[kevinkay]

YES!

Did exactly as CN 90 said - THANK YOU!

I am posting the results in case anyone else even needs this.
The smallest thread barb that would fit the rubber pipe was 1/8" FPT, I dont have FPT taps, and used a brass 1/8" FPT coupling cut in half as the "nut" (it cant be too long under), put an "o" ring on the bottom, tightened it up and holding well.
ONLY concern is that I doubled the size of the inlet hole and concerned it might affect the siphon system??
Going to drive a couple of days with the back seat off, not sure If I will order a new sender unit or keep it like this.
ALL this problem because I wanted to replace the O-ring on the siphon system that had NOT failed but doing it as preventive as I always run my tank to empty BMW Fuel Level Sensor O-Ring - Genuine BMW 16116761645
When I went to cut the squeeze ring holding the rubber hose I twisted it - and thats how I broke the plastic tube.