TheSamba.com :: View topic - Fuel sender access hole, to do or not to do?

Mon Aug 17, 2020 12:11 pm

I finally put together a YT video from the work and my experience when cutting the access hole for my fuel sender. Thought I would post it here for reference, and if anyone has questions. Give it a like if you like the content, and and consider subscribing for more - I do these videos occasionally because they are fun to show the work and nice for reference after, hope you all enjoy!

Wed Mar 10, 2021 1:52 am

Well , my fuel gauge on my 69 stopped working again and after a couple of tests it looked like my sender had packed up again.It had lasted only about a year. After pulling out the motor/tank to pop another new vdo sender for only have it last for about 3 months before it died. Out again came the motor and tank, but this time I got a genuine old one one out of a 68 bay that was being wrecked at my local Vw parts yard.I rebuilt it carefully using the right nichrome wire from my local shop and its been great for a year till it stopped working last week. Gutted I had a decision to make, drop the motor/ tank again or cut a hole in the top.After much consideration I cut a hole in the top. I put my meter over the sender and to my surprise it tested ok. Shit I just cut this hole and the bloody sender is fine. I tested further and it turned out it had lost its earth. What had happend is the sender gasket had compressed and the five bolts holding the sender in were loose as, loose enough that the earth under one of these bolts was not tight enough for a good connection. I tightened the bolts and fuel gauge is all good again.Glad I have cut this hole now as its another check I will do when checking fuel lines etc to make sure there are no leaks when tank is fill

Quote:

Wed Mar 10, 2021 9:12 am

given the quality we have to pick from today there is no way i would be pulling the whole deal apart to address this.

doing a CLEAN cut for an access is the only way to go. it takes the all day ordeal and knocks it down to 4 minutes. total no brainer in my opinion

Thu Mar 25, 2021 7:12 pm

Did you ever do this in your 71? I just scoped by fuel tank today, and ready to try this... I saw the same post you did, but have not seen anyone with measurements for the 71.

SGKent wrote: Hua Hin wrote: I cannot seem to find the exact location to cut and access hole for my sending unit on a 1971 bus? There was one remark stating that the measurements given by "someone" was incorrect for his '71 finding out "after" he cut the hole. Does anyone know where to cut the access hole on a '71 bus? Thanks for any information.

consider

Tcash wrote: Early

Late
Thanks to Speedy Jim's

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Fri Mar 26, 2021 2:33 am

The Bentley version doesn’t seem to unambiguously define the location of the hole. The locate a point in two-space but then don’t relate that point to the hole.

That, and the don’t source the elliptical hole saw

8)

Fri Mar 26, 2021 6:37 am

The hole needs to be large enough so that one's big clumsy hand can fit through the hole while holding on to the sender, and on later models it is easier to make and attach a cover if you stay aft of the bend in the rear deck a bit. Since you are using a bar to pry on the lock ring you don't need the hole to be centered directly over the sender

Fri Mar 26, 2021 8:13 am

Start by carefully drilling a hole where you think the sender is located. Look through the hole and adjust your door final location based on what you see. First though, find someone cutting up a bus and have them send you some donor metal to make your cover from

Fri Mar 26, 2021 8:27 am

Skip to about 10 minutes in my video (posted above) and you can see where my access hole lined up to the tank and sender.

Keep in mind, I have a 1972, with an FI tank, which has a sender that is offset to the passengers side.

I cut my access hole right down the center ribs.

Worked perfectly for me. I did install the CNC access hatch, nice fit and finish.

Sun Mar 28, 2021 12:48 pm

Sorry for the delayed reply, we just got hit with that tornado.. Im fine, the bus is fine. The roof on the other hand...

HUA Hin never replied back, he had the 71. So I will do as you suggested. Use page 90.4 to drill a pilot hole and then use the borescope to ensure Im in the right place. Then... cut.

1. I guess a carbide tipped hole saw is in order? about 4"? (I have a girl hand! and not a manly mit!) :lol: then just use a marine bilge cover...
2.I found a replacement sending unit made at same plant the VDOs were, (in Brazil) but appears no one had a VDO.
3. Will use Telfords tutorial on fixing my original unit as a back up.

Sun Mar 28, 2021 12:55 pm

I just used an average multi-purpose 4" hole saw from the local hardware store.

Sorry about your roof - glad you are OK otherwise (I assume.)

Sun Mar 28, 2021 1:35 pm

I did that once

Using donor metal though is better. Fits like a glove. Next time I'll probably just use sealant and not screw it down.

Sun Mar 28, 2021 3:11 pm

What year bus did you that on? Did the measurements fall inline with page 90.4?

aeromech wrote: I did that once

Using donor metal though is better. Fits like a glove. Next time I'll probably just use sealant and not screw it down.

Sun Mar 28, 2021 4:14 pm

My technique for the later buses is to use a 3/4" or 1" hole saw and drill a hole in each corner of a 4"+/- square. I then use a reciprocating saw to cut the edges of the hole.

To drill a 4" hole takes a pretty big drill motor and you can expect to have it ripped out of your hands if the bit hangs up.

Sun Mar 28, 2021 6:20 pm

I can’t swear by the measurements but it was offset about an inch to the right of centerline and almost as far forward as you can go. This was a 1972

Mon Mar 29, 2021 3:06 am

Cuccuzze wrote: Sorry for the delayed reply, we just got hit with that tornado.. Im fine, the bus is fine. The roof on the other hand...

HUA Hin never replied back, he had the 71. So I will do as you suggested. Use page 90.4 to drill a pilot hole and then use the borescope to ensure Im in the right place. Then... cut.

1. I guess a carbide tipped hole saw is in order? about 4"? (I have a girl hand! and not a manly mit!) :lol: then just use a marine bilge cover...
2.I found a replacement sending unit made at same plant the VDOs were, (in Brazil) but appears no one had a VDO.
3. Will use Telfords tutorial on fixing my original unit as a back up.

C....I would define the corners of your hole, or the edge if you are using the marine deck plate, and drill a 1 inch hole into a flat area. Much easier to manage than a 4 inch hole saw in steel. Then cut the edge with a jig saw and metal blade. Watch the stroke depth and block it up a bit if needed.

...you’ve come a long way, baby... ( my youngest of 6 ladies)

Mon Aug 07, 2023 6:35 pm

Anyone have hole locating dimensions for a 1969 bus? Thank you.

Tue Aug 08, 2023 2:32 pm

1969 should be the same as 1971

I can’t fault the access hole the guy did here but it’s way overboard in my opinion.

1) find someone cutting up a bus and buy some metal
2) using the info here mark the center of where you think the sender is located
3) drill a hole big enough so you can look with a light at the top of the sender
4) adjust your access door location
5) cut the door. I’ve used a large hole saw
6) cut the scrap metal larger than your cutout
7) lay it over the hole until it fits like a glove
8) use a pliable sealant like RTV and glue the metal down. It will be removable if needed.

Quick, cheap, and if done well won’t look bad either

Tue Aug 08, 2023 3:53 pm

why not just pull the firewall panel off the next time the engine is out and mark exactly where the sender is. It is just those screws and the two on the under side. Don't even have to pull the tank. On a late bay (1969 is not) should be able to pull the firewall with the engine in.

Wed Aug 09, 2023 6:26 am

Abscate wrote:

...you’ve come a long way, baby... ( my youngest of 6 ladies)

Are you going to find her a VW Transporter T5 or T6 motor-caravan to play with; of which there are many models from many motor-caravan converters to choose from!?! :wink: Reviews are to be found in past issues of Motor Caravan Magazine and the Caravan & Motorhome Club magazine.

Wed Aug 09, 2023 9:13 am

EZ Gruv wrote: busman78 wrote: Back in the day if you took your bus to the dealer for a sender replacement you got an access hole cut.

Any idea what they did to seal/cover the hole?

Yes I recall that VW Campaign. VW had you use a shift coupler cover plate from a Bug. I did a couple of them back in the day, I thought they looked hoakie. But the instruction sheet provided gave all the measurements required to cut the hole directly over the sender.