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

Wed Aug 09, 2023 9:14 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.

Thu Aug 10, 2023 11:09 pm

I was recently working on a 1990s Brazil Bus (bay nose, split 15 window rear)

It had a set up like this on it...and it came that way from the factory, as far as I can tell

(It had some other interesting stuff...like what appeared to be a factory zerk fitting on the clutch pedal pivot....)

Wed Apr 17, 2024 2:27 am

Using this thread I cut the hole in my early bay and after replacing my fuelsender have bent a coverplate and screwed it in place.

Wed Jul 02, 2025 12:13 pm

Reviving and old thread.

My tank and engine are out at the moment so I plan to cut fuel sender access panel while I have the chance. I plan to use one of the marine round inspection hatch. I can't decide between 4" and 6" hatch. If I align it 100% correct then I think 4" should work. 6" would give more room for error. My sender is the barrel type. so it should raise directly upward. The outer lip is about .55 - .65 inches

Opinions?

https://www.amazon.com/smartmarine-Hatch-Inspectio...T1zcF9hdGY

Wed Jul 02, 2025 12:26 pm

poundman wrote: Reviving and old thread.

My tank and engine are out at the moment so I plan to cut fuel sender access panel while I have the chance. I plan to use one of the marine round inspection hatch. I can't decide between 4" and 6" hatch. If I align it 100% correct then I think 4" should work. 6" would give more room for error. My sender is the barrel type. so it should raise directly upward. The outer lip is about .55 - .65 inches

Opinions?

https://www.amazon.com/smartmarine-Hatch-Inspectio...T1zcF9hdGY

Don't forget that one might need to gain access with yours or other people's hands, to lever the sender-unit away from its gasket after one has unfastened the small retaining bolts. I have small hands, so I only require a relatively small access hole, but even for me, a 4 inches diameter access hole might be marginal.

Wed Jul 02, 2025 1:18 pm

NASkeet wrote: poundman wrote: Reviving and old thread.

My tank and engine are out at the moment so I plan to cut fuel sender access panel while I have the chance. I plan to use one of the marine round inspection hatch. I can't decide between 4" and 6" hatch. If I align it 100% correct then I think 4" should work. 6" would give more room for error. My sender is the barrel type. so it should raise directly upward. The outer lip is about .55 - .65 inches

Opinions?

https://www.amazon.com/smartmarine-Hatch-Inspectio...T1zcF9hdGY

Don't forget that one might need to gain access with yours or other people's hands, to lever the sender-unit away from its gasket after one has unfastened the small retaining bolts. I have small hands, so I only require a relatively small access hole, but even for me, a 4 inches diameter access hole might be marginal.

Good points, I will go with 6" thank you.

Wed Jul 02, 2025 1:52 pm

this one

https://www.ebay.com/itm/263584464459

send him a request if they show out of stock. He can cnc a couple in a few hours. Lots of people use them and the are easier to install when the engine is out.

Wed Jul 02, 2025 8:29 pm

I thought about this one but in the end I didn't like the look of the finished product. I found another sold in UK that looked nice but shipping would make it expensive.

Wed Jul 02, 2025 8:59 pm

poundman wrote: I thought about this one but in the end I didn't like the look of the finished product. I found another sold in UK that looked nice but shipping would make it expensive. you can use a narrow cut off wheel and seal it with RTV. You do not want a plastic solution due to fire risk. There was carpet over that area originally. I had my auto upholstery guy make me a piece that installs with snaps so the whole area is covered.

Thu Jul 03, 2025 3:39 am

I agree with sgkent that the cnc fitted panel backer is the way to go. If, however, you really want the round inspection hatch, buy a metal one. The marine stores jack up the prices, but there are some good options in metal:
https://www.amazon.com/dp/B0FCFY5TR4/ref=sspa_mw_d...V9kZXRhaWw

Thu Jul 03, 2025 4:20 am

There is a minimal increase of fire risk with a plastic cover on a 40+ year old vehicle.