Alfa fuel tank installation

[TimBob]

I am replaceing as much of the fuel system that I can on a 1978 spider that I inherited that appears to have sat 26 years in a garage. I few questions have arisen during this project that others may have answers for. Does anyone have a recommendation for a sealant to use between the body and a new fuel tank? During installation of an in-tank fuel pre-punp, is there a type of connecting hose (e.g. silicone) that would be most durable, and finally, is there a good option for the insulation material of the wires needed to connect the pre-pump to the sending unit such that immersion in fuel will not lead to early deterioration? Any advice will be appreciated!

[Roadtrip]

Probably any kind of thin rubber insulation or even silicon sealant.

The wire insulation on the in-tank boost pump should be fuel resistant itself.

[Capp]

The correct stepped (two different I.D.'s) connector hose between pump and sender unit is a somewhat rare beast, and yes you are correct that it is a SPECIAL rubber made for constant long-term immersion. Even so, who knows if it will withstand today's modern fuel blends of ethanol/gasoline, although mine certainly has. YMMV. I found the correct Alfa OEM piece from Jon Norman's Alfa Parts in Berkeley, CA a few years ago. I didn't and you too won't like the price even if you do find it !!!
This still is preferable to using your generic "fuel-resistant" hose from your local auto parts, IMHO.
Any wire that comes packaged w/ in-tank fuel pumps and sender units should be suitable for use without modification unless you are doing something out of the norm regarding installation.

[Geoman]

You can buy a tank to body seal, such as this:

Fuel Tank Seal | Classic Alfa Romeo spare parts and accessories

but as Roadtrip said, most any rubber/caulk material would do. I used flexible caulk rope, folded lengthwise and fit just fine. It's pliable so you can wiggle the tank into it.

Frost King E/O 90 ft. Weatherstrip and Caulking Cord Grey B2 at The Home Depot

[bobh]

I just put the tank back in my 79 this weekend and thanks to advice from another thread used a product called putty tape. I purchased it at a mobile home/RV sales place. Cost was under $5.00 for at least three times the quantity needed and it comes in the appropriate light grey color.

I also replace the stepped hose on the in-tank pump. It's available at International Auto Parts, part # 17018, but like Capp said, at $39.50 I doubt you'll like the price.