I could' t get the hardware to break lose under the car and got a little impatient: omg: and cut the fuel return line. See cut black plastic hose on sender. Are these available? I was thinking about just putting a coupler near the hardware that would' t budge under the car and putting in BMW high pressure fuel hose like I run in my vanagon. Thoughts?
The kit Ian has offered is a really good deal at that price, in my opinion.
But... You will have to install the ends on the sender nipple and the flare fitting which joins the steel return line above the axle. Doing that takes some skill with boiling water or a heat gun, and you need to be very careful not to put even the tiniest scratch in the barb connection removing the old nylon from the sender.
Then, that joint over the axle may not be in the best of shape to accept the new fitting. Unless you are in California.
The thing is, the return system is much lower pressure than is implied by the use of steel and nylon. The newer cars use ordinary fuel hose (30R7 5/16) for that entire length, under axle to sender. Granted, the newer senders have the correct nipple for 5/16 hose, but if you leave the nylon you have, intact over the barb, the 5/16 hose which I believe you will only be able to get in 30R9 now, will make a good seal with any hose clamp.
Same is true for the metal line end with its flare cut off. If you have a flaring tool, you can add a bubble to the end, but I and several others have just slid it over the Bundyweld and clamped it.
Of course the saving grace is the reduced pressure here. Your original idea has merit.
Pictures here:
In the Tank