VRaptor SpeedWorks "You Dream It, We Build It!"

Fuel Tank Budget Cross-Over Kit ’04

December 24, 2015  by Shane

The parts that drive the cost up on the “standard” fuel cross-over kits are the pressure-sealing washers.  I’ll be right up front with you….MY COST on them is about $14 EACH…..plus shipping!  Two washers come in each kit, so we have $30 wrapped up in just 2 pressure sealing washers.  They are excellent washers that provide a positive seal….no doubt about it!  These washers have a rubber seal moulded directly to a steel washer that prevents the rubber seal from “squishing out” from behind the AN fitting and opening up a place for fuel to leak.

If you’re watching you pennies and you’re looking for a cheaper solution that….when installed correctly….will provide every bit as positive of a seal for your fuel tanks, this is the solution for you.  Instead of the seal being moulded directly to a steel washer, this kit has 4 of the square cut O-rings, along with some “retainer rings” that fit snug on the OD of the square cut O-rings.  You would install the square cut O-ring on your AN fitting, along with one of these retaining rings, and then put the fitting thru the tank.  Place another square-cut O-ring on the inside followed by an aluminum washer followed by the nut.  Position the retaining ring right in the center of the square-cut O-ring and tighten the nut.  As the nut is tightened and the square-cut O-ring attempts to “squish out” it securely locks the retaining ring in place so it can not move, while the retaining ring prevents the O-ring from being able to squish out from behind the AN fitting to cause a leak.

This kit contains:

4 –  Square Cut O-rings

2 – Aluminum O-ring “Retainer Washers”

2 – Aluminum washers

Please Note:  The aluminum “block off” plate shown in the bottom 3 photos is NOT included in this kit.  Shown only so that you can see how these parts will be assembled into the holes you drill in your ’04 tanks.

Positive seal.  Lower cost.


Installation note:  DO NOT OVER-TIGHTEN!  The nut that secures the AN fitting to the tank or aluminum plate only needs to be tightened enough to pinch the outer O-ring between the AN fitting and the tank or aluminum plate.  As long as the outer O-ring is bulged enough to lock the “retainer washer” in place, no further tension is required.  If you over-tighten the nut, the O-ring inside the tank will tear in half and squish out from behind the aluminum washer and you will end up with no seal.  You can use the bottom 3 photos below as a good guide as to how the O-rings should look when properly tightened.



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