Hack Job Sending Unit

[alldodge]

Been thinking about this and I think I have a better idea, and should be real safe to do. The original Tank has 3 holes which work fine. Its the other 2 holes that's causing the issue.

What about a small piece made up just to under the lip of the tank sender hole? Cut drill then and tap the holes. Use longer screws on those 2 so they will be easier to start in the piece of stock.

Use some adhesive and insert the piece inside the tank hole and up against the under side. Adhesive doesn't need to be permanent, just hold if enough so you can slide the sender in and get the 2 screws started.

Once the 2 have been started and gasket is on top, your home free. If the adhesive gives out its of no issue because the 2 screws will hold and allow it to be tightened. The shinny spot not quite all the way thru will need to be opened up so screw will go thru and into plate behind it

 

[nola mike]

Been thinking about this and I think I have a better idea, and should be real safe to do. The original Tank has 3 holes which work fine. Its the other 2 holes that's causing the issue.

What about a small piece made up just to under the lip of the tank sender hole? Cut drill then and tap the holes. Use longer screws on those 2 so they will be easier to start in the piece of stock.

Use some adhesive and insert the piece inside the tank hole and up against the under side. Adhesive doesn't need to be permanent, just hold if enough so you can slide the sender in and get the 2 screws started.

Once the 2 have been started and gasket is on top, your home free. If the adhesive gives out its of no issue because the 2 screws will hold and allow it to be tightened. The shinny spot not quite all the way thru will need to be opened up so screw will go thru and into plate behind it

View attachment 366167

Except next time you remove the sender, "plop" into the tank?

 

[Slickcraft235]

Except next time you remove the sender, "plop" into the tank?

Yes, it's an ingenious fix for sure, but I think I'm going to stick with mounting a 4" plate. So what about my 3 mounting questions? Thanks in advance, Chris

 

[alldodge]

Except next time you remove the sender, "plop" into the tank?

Don't of many that have ever needed to replace the sender, and even less that needed to replace it twice

I would clean the tank top to bare aluminum, then use JB weld. With JB the plate will not need more then 3 holes. The plate will be need clearance holes and the tank would be tapped.

If using a gasket, I would tap at least 5 holes, maybe 6

Keep in mind you need to align the sender holes with the new ones on the plate. So that one spot where it wasn't drilled thru completely will need attention

Old holes need to be drilled larger, or new holes need to be tapped with plate on top of tank. Will need to be tapped on top because threads may not align close enough to thread clean thru.