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bytes311
05-15-2019, 02:37 PM
Hello all,

My fuel distributor has a tiny notch/score at the banjo fitting for the return line, and no matter how tight I get it, the crush washer can not make it a perfect seal. The PO put a little rubber o-ring between the crush washer and the fuel distributor which I wasn't aware of until I started the process of replacing the original return hose.

Is there an epoxy resin or a filler that's gas resistant that I can use to seal up that notch?

Thanks!
dn010
05-15-2019, 02:38 PM
Might be easier/safer to file it down flat.
vwdmc16
05-15-2019, 03:47 PM
Bad idea, I know you are very keen on keeping OEM looking lines but it's not worth the risk of the car burning down to keep it. Please buy new hoses, hell I'll give you my old return fuel hose for free.
dn010
05-15-2019, 03:52 PM
Bad idea, I know you are very keen on keeping OEM looking lines but it's not worth the risk of the car burning down to keep it. Please buy new hoses, hell I'll give you my old return fuel hose for free.

The fuel distributor itself has the score, not the line:


My fuel distributor has a tiny notch/score
bytes311
05-15-2019, 03:57 PM
The fuel distributor itself has the score, not the line:

Correct. I do have a new hose, it just won't seal properly with that tiny notch in the FD. I could sand it down as that was also my first thought, but I wanted to hear other opinions. :)
Ron
05-15-2019, 05:23 PM
+1 Dan


I could sand it down as that was also my first thought, but I wanted to hear other opinions. :)

Don't sand it -- Use a file wide enough dress the whole area, square, with each stroke. Otherwise it will probably still leak.
bytes311
05-15-2019, 06:17 PM
+1 Dan



Don't sand it -- Use a file wide enough dress the whole area, square, with each stroke. Otherwise it will probably still leak.

Okay, thanks!
David T
05-15-2019, 10:24 PM
File it as flat and square as you can. You should not have to remove much. Put a piece of paper inside to keep the metal particles from getting inside as you file.
bytes311
05-16-2019, 10:45 AM
File it as flat and square as you can. You should not have to remove much. Put a piece of paper inside to keep the metal particles from getting inside as you file.

Thanks David!