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Old 03-25-2009, 10:53 PM   #61
Duct_Taper
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Turns out it isn't the vent line to the front of the car. Looking at the diagram again, it's the fuel return line from the expansion tank to the fuel tank. See realOEM diagram and my pic (labeled).

I think I need to drill a new hole and attach a new pipe in it somehow.
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Old 03-25-2009, 11:03 PM   #62
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Again, not entirely necessary IMO but I would do it if I were in your shoes. Perhaps just drill a hole and tap a brass NPT 90 degree fitting or something? Doesn't need to be strong, just leak free. Its only going into the thin sheet metal but it might do. *shrugs*

Or use gas tank repair putty. I used that to repair a massive leak while wet with gas once, from CT for about $5. Its hard enough to drill and tap when cured. I bet just putting it around the pipe going into the hole would do.

I think I like the 2nd option better.
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Old 03-25-2009, 11:10 PM   #63
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Yeah, I think the plan is to plug the current hole w/ the gas tank repair putty, drill a new hole, and seal a fuel line (or NPT fitting) in it w/ the repair putty.

Doesn't need to hold pressure or anything, just has to not leak.
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Old 03-27-2009, 08:49 AM   #64
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Well, I attempted the fix last night. I think it should work, but I'll have to wait until after the weekend to install it and find out.

Ended up sealing the holes with the gas tank repair putty (pretty cool stuff) and drilling a hole for a 1/8" NPT elbow with a 1/4" hose barb fitting on the other side to hook up to the line in the car. Sealed the connection to the tank with more putty.
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Old 03-27-2009, 01:08 PM   #65
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Hopefully that works out for you; I'm sure it will. That gas tank repair stuff is neat-o; it really saved my ass in a pinch.
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Old 03-27-2009, 03:17 PM   #66
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Yeah, I think it should work OK as long as that line was my only leak (I think it probably was).

The putty is pretty wild - hardens up amazingly quickly (seemed fairly solid in an hour, and completely cures in 2 according to the instructions), and seems to stick pretty well too!
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Old 05-13-2009, 07:27 PM   #67
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Well, I figured it was time for another update... been driving it now for ~2500 kms with various issues being found and dealt with, and I'm almost happy with it now. Finally got the summer wheels re-painted and on the car today, only to discover that my mechanic used lip weights to balance them on the inside lip and the front wheels interfere (just barely) with the struts.

I'm taking the front wheels back in tomorrow morning to get re-balanced using stick-on weights.

As for the painting... I'm reasonably happy with how they turned out. Definitely not a professional job, but waaay better than they were before.

Anyway... pics:
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Old 05-13-2009, 08:56 PM   #68
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The car looks great man.
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Old 05-15-2009, 03:30 PM   #69
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Wow, looks great!
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Old 05-15-2009, 03:33 PM   #70
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Yeah, looks awesome!
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Old 05-15-2009, 05:40 PM   #71
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Thanks guys!

It's been a lot of work but I'm reasonably happy with it now... at least for this summer
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Old 05-15-2009, 07:43 PM   #72
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Have you thought about getting an 'is lip? It'd complete the look.
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Old 05-15-2009, 08:22 PM   #73
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Yeah - I'm actually going to look for a Volvo lip... same look, much cheaper.
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Old 05-15-2009, 09:32 PM   #74
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Volvo lip is awesome. I love cheap shit that still looks good that like.
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Old 07-17-2009, 03:00 PM   #75
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Some new pics of the vert, now with RD wheels (still no Volvo lip, but I might be picking one up this weekend):

http://www.maxbimmer.com/forums/showthread.php?t=122801
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