R230 Fuel Tank Baffle Repair

[Conor]

Sounds like the baffle has broken away from both welds, top and bottom that could be a right pain.

Yeap. Need to get a look in.

 

[00slk]

Those inspection cameras are worth their weight in gold

 

[Conor]

Those inspection cameras are worth their weight in gold

Yea, I agree. Good tool kit to have. I've kind of resisted up to now. I did have a cheapo Bosch one from Amazon but returned it as it wasn't great.

I think at some point i'll invest in a decent unit. I wonder which one is good.. Perhaps tool time Tim @Chrishazle might have some input.. For some reason I have you down as the authority on tools here, Chris

 

[00slk]

I have a cheapo one I got from lidl, had it now over 6 years and have used it quite a bit, especially good for checking cavities in teeth

 

[Conor]

I have a cheapo one I got from lidl, had it now over 6 years and have used it quite a bit, especially good for checking cavities in teeth

Oh I must check that. Was curious what it would be like? Assume it's good.

 

[Blobcat]

I have a cheapo one I got from lidl, had it now over 6 years and have used it quite a bit, especially good for checking cavities in teeth

I’ve the same one, you obviously didn’t read the manual... specifically advises against using it in body cavities...

 

[00slk]

Oh I must check that. Was curious what it would be like? Assume it's good.

For what we paid it's not too bad and has worked for me every time I've needed to find something in awkward places The picture focus is quite reasonable but if you magnify it fully and try accessing narrow space it can be a little challenging
Summed up it'll do me

 

[00slk]

I’ve the same one, you obviously didn’t read the manual... specifically advises against using it in body cavities...

You party pooper Russ.......Not been to some of the parties then?

 

[Conor]

You party pooper Russ.......Not been to some of the parties then?

There is a slight chance you might be talking about different parties.. @00slk why don't you elaborate on the party you are referring to, in order to avoid confusion

 

[00slk]

There is a slight chance you might be talking about different parties.. @00slk why don't you elaborate on the party you are referring to, in order to avoid confusion

 

[SL63 Mark]

OK folks I've got some good news on this. I decided to have a go at fixing my banging fuel baffle, I read all the how to guides on the internet, how hard can it be I thought.

So after a few weeks thinking about it, I didn't like the spring idea, too uncontrolled, and possibility of sparks and corrosion, so I thought, what would work well in a fuel tank, ah yes, copper wire. I have a roll of 1.5mm copper wire I have left over from another project. So I used up as much petrol as possible, took the car outside, got my fire extinguishers handy, disconnected both batteries (the last thing you want is a spark), removed all the boot lining and exposed the tank. I removed the sender and peered inside, but I could barely see the loose baffle. How the hay do I get a copper wire round that ? So I made a loop in the wire, and made a double hook in a coat hanger, looped the wire round the gap in the baffle (see photo) and pulled the wire through. Fortunately copper is very ductile and malleable and easy to work with, it also cannot cause sparks or corrode (much) so in theory it is the perfect material (it seems to me). Once I had the copper wire round the baffle I pulled it tight (not too tight mind you) and tied it round the sender taking great care to avoid the electrical contacts, otherwise the fuel gauge will not work. Replacing it all is pretty fiddly, but I did it, and hey presto, no more bonging.

Hope this is of help to someone.

 

[SL63 Mark]

Here's another photo of the general area, showing the access you have. I sat on the edge of the boot, quite comfortable actually.

 

[John Laidlaw]

Nicely done!

 

[Conor]

It's fantastic! I'll be back to this thread (...aaand all the others) later this year.

 

[SL63 Mark]

Nicely done!

Thanks John, I'll let you know how it holds up. Hopefully there'll be no more trouble, (unless one of the other spot welds lets go)

 

[dave140]

Thought id share a picture of another successful fix i did yesterday on a forum members car.

View attachment 62291

Hi Raj. Are you still offering to repair the fuel tank baffles? if you are, can you let me know how much and how long it takes please? I live in Walsall so easy to travel to you. Thanks.

 

[-raj-]

Hi Dave,

Yes i do, i will send you a PM.

 

[norman whiting]

OK folks I've got some good news on this. I decided to have a go at fixing my banging fuel baffle, I read all the how to guides on the internet, how hard can it be I thought.

So after a few weeks thinking about it, I didn't like the spring idea, too uncontrolled, and possibility of sparks and corrosion, so I thought, what would work well in a fuel tank, ah yes, copper wire. I have a roll of 1.5mm copper wire I have left over from another project. So I used up as much petrol as possible, took the car outside, got my fire extinguishers handy, disconnected both batteries (the last thing you want is a spark), removed all the boot lining and exposed the tank. I removed the sender and peered inside, but I could barely see the loose baffle. How the hay do I get a copper wire round that ? So I made a loop in the wire, and made a double hook in a coat hanger, looped the wire round the gap in the baffle (see photo) and pulled the wire through. Fortunately copper is very ductile and malleable and easy to work with, it also cannot cause sparks or corrode (much) so in theory it is the perfect material (it seems to me). Once I had the copper wire round the baffle I pulled it tight (not too tight mind you) and tied it round the sender taking great care to avoid the electrical contacts, otherwise the fuel gauge will not work. Replacing it all is pretty fiddly, but I did it, and hey presto, no more bonging.

Hope this is of help to someone.

View attachment 64784

Hi Raj. Are you still offering to repair the fuel tank baffles? if you are, can you let me know how much and how long it takes please? I live in Walsall so easy to travel to you. Thanks.

Thought id share a picture of another successful fix i did yesterday on a forum members car.

View attachment 62291

Hi Raj

 

[norman whiting]

Hi Raj. Are you still offering to repair the fuel tank baffles? if you are, can you let me know how much and how long it takes please? I live in Walsall so easy to travel to you. Thanks.

Hi Raj, can you get in touch with me to fix similar please.

 

[-raj-]

Hi Norman, Sure i will message you.