Sheared off studs on Petrol tank fuel filter fitting

[stevebrooker58]

Hi Guys,

Hoping for some ideas suggestions for an issue on my 2003 R1150 GS.

In the process of changing the fuel filter whilst removing the filter and pump mounting plate three of the studs sheared.

Any suggestions for a fix solution.

Thanks in advance

 

[Neil W]

Two possible options , I've done both which worked ;

1. with a guaranteed totally empty and flushed and vapour free tank.............. grind off remainder of studs and then weld/braze on replacement studs made from cap head bolts with most of the head ground off to form a flat surface.

2. again with an empty vapour free tank grind off the remains of the studs ...drill out the studs and replace with a cap head bolt fitted from the inside of the tank and secure with a liquid metal.

Thirdly and not tried by me but you could try rivet nuts .

If you try either of the first two and do not make 110% sure that the tank is vapour free and blow yourself up DO NOT blame me

 

[JohnnyBoxer]

Grease the nuts and threads up on reassembly

 

[Timolgra]

Grease the nuts and threads up on reassembly

When was the last time you changed your own fuel filter? I thought you had a man for that

 

[JohnnyBoxer]

When was the last time you changed your own fuel filter? I thought you had a man for that

I do and he did..................yesterday, very impressive

I'd ask you if you were nearer

 

[Tractors are go]

Two possible options , I've done both which worked ;

1. with a guaranteed totally empty and flushed and vapour free tank.............. grind off remainder of studs and then weld/braze on replacement studs made from cap head bolts with most of the head ground off to form a flat surface.

2. again with an empty vapour free tank grind off the remains of the studs ...drill out the studs and replace with a cap head bolt fitted from the inside of the tank and secure with a liquid metal.

Thirdly and not tried by me but you could try rivet nuts .

If you try either of the first two and do not make 110% sure that the tank is vapour free and blow yourself up DO NOT blame me

You can also run a hose from running car exhaust into tank, files it with CO2 or fill tank with water then braze it.

If it goes tits up, definitely Neil's fault.

Sent from my SM-G925F using Tapatalk

 

[mikeyboy]

If you can swallow the postage,
I can get a permanent repair done for you.
Mike

 

[stevebrooker58]

Hi Guys,

Thanks for the replies chose to drill through , tapped thread and screwed through from inside the tank liberally coated heads of bolts with plastic metal , currently waiting for this to cure for a few hours before i put fuel in.

Thanks for the assistance fingers crossed.

Steve

 

[KTM-AL]

Hi Guys,

Thanks for the replies chose to drill through , tapped thread and screwed through from inside the tank liberally coated heads of bolts with plastic metal , currently waiting for this to cure for a few hours before i put fuel in.

Thanks for the assistance fingers crossed.

Steve

Hi Steve
Can you please let us know how you get on ? Lots of threads are never finished, so we never know the outcome.

 

[stevebrooker58]

Hi KTM-AL,

As requested feedback on my repair when I filled the tank initially I had a small weep of petrol from the lowest bolt , so I emptied the tank again and used a different make of plastic metal as the original application was quite runny although it went off within a few minutes it ran away from the bolt head and obviously left a small gap. The other make was a paste and easier to use as I was able to mould it around the bolt area better , although it took longer to cure 24hours. Filled tank this afternoon and it did not leak so the repair looks good .

Again thanks to all for suggestions and advice .

Steve