Fitting a fuel gauge sender?

[nigelmercier]

I previously mentioned problems with my fuel tank: apparent loss of capacity, a faulty sender unit, and the need for a dipping point.

I've now bought a new sender unit, exactly the same as the old one. I plan to mount this in a new location, and use the old mounting as a dipping point (or vice versa).

The fitting consists of a pair of flanges, one with a cut-out in the side to enable it to pass though the hole in the tank - see attachment. This set of instructions says to cut a 60mm hole, but if I do this then the screws will be inside the large hole with the flanges only just resting on the edges. I have other instructions that say to cut a 43mm hole, but then the inner flange won't go through! I'm sure I will figure something out... [Later] If figure the best way is to cut a 43mm hole, but with two notches: one at each end of the diameter.

The existing inner flange and gasket seem to be held in place: it stays put when I remove the screws. Is there some kind of mastic I can use that won't be eaten by diesel?

 

[lenseman]

. . . . . This set of instructions says to cut a 60mm hole, but if I do this then the screws will be inside the large hole with the flanges only just resting on the edges. I have other instructions that say to cut a 43mm hole, but then the inner flange won't go through! I'm sure I will figure something out... . . . .

Cut a hole NO LARGER than the diameter measured across the inner flange, from the middle of the 'flat' on the inner flange to the diametrically opposite edge of the inner flange.

This will allow the inner flange to pass into the tank and you will still have enough 'land' to be able to correctly fit the fixing bolts.

Use blue Hylomar ( a Roll-Royce product).

 

[RestlessL]

I had a similar problem when I fitted my gauge. The instructions said to cut the smaller diameter hole, and then cut two notches diametrically opposite to allow the flange to pass through. However, in the end I cut a small sector out of the flange.

2 tips - tie some strong tread to the flange so you don't loose it, and get some very long screws.

John

 

[nigelmercier]

Use blue Hylomar ( a Roll-Royce product).

Thanks, I contacted them and they said: "Our Technical Department have recommended Hylosil Instant Gasket for this application"

 

[lenseman]

Thanks, I contacted them and they said: "Our Technical Department have recommended Hylosil Instant Gasket for this application"

You need to ask if you can be sent a sample tube.