Re: fuel pipes. I recently discovered to my dismay that the alleged high quality silicon fuel lines, are in my opinion ‘not fit for purpose ‘. I found out the hard way when recently finishing the restoration on my Beta coupe. I replaced every fuel line and hose on the car using original spec cotton braided hose in some places and silicon in others. The smell of fuel was overwhelming. After trial and error I discovered that Silicon hoses ‘breath’ regardless of the superior quality claims made by manufacturers and sellers. It was truly unbearable.
All silicon now replaced with quality gates fuel hoses and problem solved.
The other thing I noticed with your chassis rail problem is the lack of spacers between the fuel tank and the chassis. I’m pretty sure when I dropped my tank last year there where large thick spacers between the tank and the chassis. I think they are aimed at spreading the weight of the tank against a larger surface area on the chassis rail to prevent the problem you’ve just had of pulling the studs out of the chassis rail.
The spacers on my car where something like 4mm thick 20mm in diameter. (I’ve not measured this, just from memory). Without them I think the rubber foam seal around the sender is pushing the tank down even harder against the mounting studs.
Has anyone else got these spacers fitted.
All the best
Ian