1961 FI (Fuel Injection) Fuel Meter

**William C.** · July 19, 2004, 10:09 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

Whee is the crack? The most usual place is the the cover at the fuel inlet. The fuelmeter cover is aluminum and can be welded. The damaged thered may be helicoiled, or filled with a good metal epoxy and drilled and retapped, depending on which one is stripped.

**William C.** · July 19, 2004, 10:09 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

Whee is the crack? The most usual place is the the cover at the fuel inlet. The fuelmeter cover is aluminum and can be welded. The damaged thered may be helicoiled, or filled with a good metal epoxy and drilled and retapped, depending on which one is stripped.

**Matthew Hirschler** · July 19, 2004, 10:23 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

On the top of the fuel meter, there is a 90 degree elbow that goes down into the meter from the fuel filter. when viewed from the passenger side of the car, there is a flat circular area (~3/4 in dia.). In between these two areas there is a ridge. The crack is between the elbow and the ridge, but moreso on the ridge itself; it runs side-to-side, not front-to-back.

The thread is the most forward large screw (the third from the back, on the outside.

**Matthew Hirschler** · July 19, 2004, 10:23 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

On the top of the fuel meter, there is a 90 degree elbow that goes down into the meter from the fuel filter. when viewed from the passenger side of the car, there is a flat circular area (~3/4 in dia.). In between these two areas there is a ridge. The crack is between the elbow and the ridge, but moreso on the ridge itself; it runs side-to-side, not front-to-back.

The thread is the most forward large screw (the third from the back, on the outside.

**William C.** · July 19, 2004, 10:28 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

Can you post a picture of tne crack, the thread is a relatively minor issue

**William C.** · July 19, 2004, 10:28 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

Can you post a picture of tne crack, the thread is a relatively minor issue

**Dennis C.** · July 19, 2004, 10:37 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

If the repair story has a sad ending, I believe this cover is available in reproduction.

**Dennis C.** · July 19, 2004, 10:37 AM

Re: 1961 FI (Fuel Injection) Fuel Meter

If the repair story has a sad ending, I believe this cover is available in reproduction.

**DANNY PANTUSO** · July 19, 2004, 01:29 PM

Re: 1961 FI (Fuel Injection) Fuel Meter

Hi Mattew, There David Skiados in Cary, North Carolina 27511 this guy is good David did my Top flight fuel injection unit on my 63 z06, His # is 919-4604669 . Danny Pantuso

**DANNY PANTUSO** · July 19, 2004, 01:29 PM

Re: 1961 FI (Fuel Injection) Fuel Meter

Hi Mattew, There David Skiados in Cary, North Carolina 27511 this guy is good David did my Top flight fuel injection unit on my 63 z06, His # is 919-4604669 . Danny Pantuso

**Jerry G.** · July 19, 2004, 08:55 PM

Re: John Degregory has beautiful repo *NM*

**Jerry G.** · July 19, 2004, 08:55 PM

Re: John Degregory has beautiful repo *NM*

**G B.** · July 19, 2004, 09:05 PM

Fuel meter repair

Matthew, you sound like a confirmed do-it-ur-selfer, so I won't say anything about getting in over your head. We are all manly men here who can fix every single thing on our cars by ourselves, right?

First, remove the cover from the fuel meter carefully to avoid damaging the axle link or main diaphragm. Use your Dremel tool to deeply V-notch the crack. Use aluminum rod with your heli-arc welder to fill in the crack front-to-back. This will probably require completely sealing up the fuel inlet hole. After air cooling, grind down the excess weld material to expose the porosity pits. There will certainly be such pits because the cover is not made of pure aluminum. It has elements of zinc and trash it in that will form gas bubbles as you weld. Keep going back over it until the only porosity pits left are very small. Using the Dremel tool again, sculpt the outside surface back into the original contour. Use 400 grit sandpaper to leave a smooth finish. After drilling and re-tapping the fuel inlet hole, re-surface the diaphragm seat area on a pane of glass using 220 grit sandpaper lubed with WD-40. Give the cover a nice finish and a uniform color by putting it in a vibratory drum full of Mineral Spirits and small ceramic beads for about an hour.

As far as the stripped threads in the bowl, use your 10-32 heli-coil kit to repair that hole. Check the other screw holes for the upper fuel meter bracket closely. Some of them may be partially stripped too.

If you want to buy a reproduction fuel meter cover, get the one sold by John DeGregory. You can contact John by e-mail through his profile on this board or look up his phone number in his Driveline ad. Do NOT, under any circumstances, buy and try to use the soft reproduction cover made of pewter and sold by others.

**G B.** · July 19, 2004, 09:05 PM

Fuel meter repair

Matthew, you sound like a confirmed do-it-ur-selfer, so I won't say anything about getting in over your head. We are all manly men here who can fix every single thing on our cars by ourselves, right?

First, remove the cover from the fuel meter carefully to avoid damaging the axle link or main diaphragm. Use your Dremel tool to deeply V-notch the crack. Use aluminum rod with your heli-arc welder to fill in the crack front-to-back. This will probably require completely sealing up the fuel inlet hole. After air cooling, grind down the excess weld material to expose the porosity pits. There will certainly be such pits because the cover is not made of pure aluminum. It has elements of zinc and trash it in that will form gas bubbles as you weld. Keep going back over it until the only porosity pits left are very small. Using the Dremel tool again, sculpt the outside surface back into the original contour. Use 400 grit sandpaper to leave a smooth finish. After drilling and re-tapping the fuel inlet hole, re-surface the diaphragm seat area on a pane of glass using 220 grit sandpaper lubed with WD-40. Give the cover a nice finish and a uniform color by putting it in a vibratory drum full of Mineral Spirits and small ceramic beads for about an hour.

As far as the stripped threads in the bowl, use your 10-32 heli-coil kit to repair that hole. Check the other screw holes for the upper fuel meter bracket closely. Some of them may be partially stripped too.

If you want to buy a reproduction fuel meter cover, get the one sold by John DeGregory. You can contact John by e-mail through his profile on this board or look up his phone number in his Driveline ad. Do NOT, under any circumstances, buy and try to use the soft reproduction cover made of pewter and sold by others.

1961 FI (Fuel Injection) Fuel Meter

1961 FI (Fuel Injection) Fuel Meter

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