62 Fuel Injection leak

[Steve P.]

I just got my car back from restoration and was fortunate to get Top Flight at the recent Arizona Regional meet. I towed it home in an enclosed trailer and when I open it up to take the car out there was the smell of gas. I found what looked like the leak near the right side of the fuel bowl, perhaps by what looks like a plug. I'm not that familiar with the unit yet but every time I start it up to take it out the leak come back and I can't quite see where it's coming from.
Anyone have a similar experience?

[Don H.]

Re: 62 Fuel Injection leak

I would suggest doing a very good cleaning before you start it again so you can be sure where the leak is from. It could be the plug in the side of the fuel meter or many other places. BE SURE YOU HAVE A FIRE EXTINGUISHER HANDY and be careful! Once you know where it is leaking then you can plan a repair. Good luck, Don H.

[John D.]

Re: 62 Fuel Injection leak

Steve, Be very careful as more FI cars catch fire because of a plug on the size of the fuel meter. I just removed a nickel from one. The plug is the exact size of a .05 Maybe the OD needs sanded a touch though.
The leak from the plug should be obvious. If it falls out (as some do) then it's all over.
Send us a pic of the leak area.
Could also be rubber o'ring leaking near that plug. The copper supply line going from the fuel bowl to the spider. The spider is the copper line assembly that feeds the spider. It's actually called a Fuel Distributor but that term has been lost forever. Just call it a spider.

Best way to install a new welch plug (round plug) is to epoxy it IN. Not smear epoxy on the outside like I have seen.
In any case do not drive the car until fixed. John

[Richard M.]

Re: 62 Fuel Injection leak

John, This Welch plug, correct? It always seemed strange to me that his plug is there. Is the hole for some other application, or just a casting access hole for machining internal areas?

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When Chuck and I worked on this unit last year we replaced it and did as you suggested. He said it was alway a common leak point on these.

Interesting you found a real 5 cent piece in one there.

Rich

[John D.]

Re: 62 Fuel Injection leak

Hi Rich, I have seen enough 5 cent pieces to buy at least one cold one.
Meanwhile I hate to say this but that's not how a welsh/welch plug should be installed. Simply dented the center of the plug doesn't do much. One needs to use a punch that is almost the diameter of the plug. Then when you smack it with a light weight hammer about 3 times the plug will spreaddd. I imagine RP used an hydraulic press to put them in. I can remember in the old days brand new cars had signs of seapage around this plug. Gas stains.
As far as why it's there in the first place I guess it has to do with the spill valve area. No one ever said but it is a royal pain and lots of cafrs were burnt to the ground because of that.
Story: Years ago an insurance adjuster came to my shop from Ohio. He brought a toasted 62 Fi unit that had done severe damage to the car.
The adjuster or some kind of agent set it on my workbench. I looked at it for a second or two and pointed out to him how the fire started.
He acted a little cocky and said. Just who do you think you are that you can tell us in a second how the car started when now of the others in our office knew.
I gave him a very polite answer. said notice the plug is missing!!!!!! Notice the path of the fire melting all the castings and nozzle blocks. Notice how pristine the drivers side of the unit is. He then asked me how much it would cost to fix the damge and I said it's totalled sir. True story. Old JD

[John D.]

Re: 62 Fuel Injection leak

Our Pittsburgh Tri-State chapter is always needs tech articles for our newsletter.
I think I will write on this welch plug thing. As soon as I find out if the proper spelling is welsh plug or welch plug. How me out please guru's. John

[Jim L.]

Re: 62 Fuel Injection leak

I always thought that Welch plugs were the cup-shaped plugs, like one finds in the sides of engine castings and that the domed plugs were called expansion plugs.

But I've been wrong about a lot of things and this might be just another example.....

[Vinnie P.]

Re: 62 Fuel Injection leak

Our Pittsburgh Tri-State chapter is always needs tech articles for our newsletter.
I think I will write on this welch plug thing. As soon as I find out if the proper spelling is welsh plug or welch plug. How me out please guru's. John

I do hope you also send it to me so all 15,500+ members can benefit from your expertise and not just the 100 or so that get to read a chapter newsletter...

Thanks John
Vinnie

[Richard M.]

Re: 62 Fuel Injection leak

JD, I'll take your advice and redo that one. I'll have to get another one as there was only one in my kit.

Jim, I just found a photo of the bag it came in......says "Welch Plug".

Rich

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[Steve P.]

Re: 62 Fuel Injection leak

Thanks John. here are some pictures and you can see a little seepage from the area. This unit was rebuilt by Podell last May and put on the engine at that time. The engine was on the chassis and we were trying to get ready for Bloomington but ran out of time. We pulled back a bit then ramped up to get ready for the AZ Regional and made it so the engine has not run hardly at all. Is this a common problem?
You scared the heck out of me regarding fire and here's my predicament; I'm entered in the Seal Beach (CA) car show on the 25th but I work late and will be gone this weekend so won't have time to do or have any work done. The show is only 5 miles away from the house... is this still as big a risk as you thought? If so, any quick fix suggestions? I certainly won't start it until the morning of the show... These were taken before I cleaned it all off and after it had run a couple of times.
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[Bill W.]

Re: 62 Fuel Injection leak

John . I've had the fuel injection on my 62 sense the mid 80s .. I drove home one night after about a 15 mile drive from a car show . When I pulled in the driveway and got out to open the garage I smelled gas , I shut the engine off & opened the hood The right side of the intake and top of the valve cover had gas standing on it . the exhaust manifolds were glowing red in the dark due to the 4.11 rear and 65 mph speeds . I guess the only reason it didnt catch on fire is the poor quality of the gas and dumb luck . The new plug is epoxied in . Looks like hell but it dont leak . The unit has only had one rebuild by me with parts I got from you. Runs great until it gets about 90 outside then it wont idle . I always carry a fire extinguisher .

[Mike E.]

Re: 62 Fuel Injection leak

The 62 Gulf racer blew out the welch plug in a run through the neighborhood back in about 1986. No fire. Lots of panic. Proactive maintenance on any fuelie I've had since.

[Steve P.]

Re: 62 Fuel Injection leak

Someone suggested a thin film of JB Weld around the perimeter to hold for the car show since it doesn;t seep or leak when the car is just sitting. Any thoughts?

[John D.]

Re: 62 Fuel Injection leak

Steve, I tried JB weld over the years. Its a great product but not for this application. Peels off. Should get you thru the show though. John

[Jim L.]

Re: 62 Fuel Injection leak

Jim, I just found a photo of the bag it came in......says "Welch Plug".

Rich et all,

I guess I've been wrong all these years.

I just did a search for "expansion plugs" on the NAPA web page and a plethora of cup plugs showed up. And when I searched for "welch plugs", the domed variety popped up.

Oh well.....

Jim