Leaking fuel from tank at sender

[juicejug]

I'm not sure if this is the proper forum, please let me know if there's a better forum for this question.

I recently replaced my fuel sender on my 84 18' Sea Ray Seville. When I removed the old sender, there was 1 screw that was very loose and it appears as if the hole is stripped. When I put the new sender in, it is definitely leaking some fuel from this spot.

I'm wondering what SAFE options I may have to repair this rather than replace the entire tank. I've seen at the hardware store some mesh that is used specifically for this purpose, where you place it over the hole, then thread the screw in and the mesh fills the gaps where the threads are stripped. I'm hesitant to use this as it's not noted if it's safe for fuel type uses. I don't know if it will somehow make sparks. I've also considered tapping with larger screw sizes, but once again am not certain of a SAFE way to do this.

Does anyone have any suggestions?

 

[Scott Danforth]

I would go to next size larger screw.

 

[hemi rt]

What does the screw screw into - metal, plastic, etc. If it screws into metal and you have some room to work you could install a helicoil to repair the thread back to the original size or you could tap it to the next size up if there is enough metal to do it.

 

[juicejug]

The tank and the sender collar are both aluminum.

Will that be safe?

 

[mjf55]

Tank material too thin to tap and thread. Just do as Scott said and use the next size screw. You will be able to tighten it up so it wont leak.