Fuel sender access hole, to do or not to do?

[BayJay]

don't suppose you took any pictures of the accessibility with the firewall off? Is that how you got to it? Through the firewall and then lifted it out and to the left (towards driver side). I think that's what you're saying.

I need to do this and have a 1979 Westy. Would be great if I can do this at the same time I replace all my fuel and vapor lines and don't have to cut an access hole.

[Wildthings]

[Hoody]

Well said. We need a tutorial how to tweak the new VDO fuel senders so that they show an accurate fuel level with the tank out of the bus. I can't understand why no one has tried putting in a bullet proof piece of tubing where the pesky one leaks behind the firewall. Some say it's just good bussiness to change your fuel lines annually. the one behind the firewall is probably responsible for more fires than any other. The long and short of it is if your not really carefull with these engines regularlly they will let you down. That being said if you pay close attention to detail and follow the original German engineers service advice...it will last forever.

[pkrboo]

thk this is the neatest way I have seen of doing an access hole:

http://thelatebay.com/index.php?topic=660.0
_________________
1979 Sage Green Westfalia P22

[Chris_914]

[SGKent]

vw made a special metal plate to make an access hole. It is covered in the factory manual. The best one I have see is a square plate mounted from below then a piece of the corrugated metal lying on top of it screwed in with countersunk screws.

As for tweaking a new sender, with the tank out and connected, (beware of static electricity) you have to drain the tank and come in with a wooden pole or yardstick from the fill side then lift the sender all the way up. See where it reads and adjust. It takes several tries but one can get it right. Would not surprise me that the sender is used in many models and older ones have to be calibrated.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[BayJay]

[HarryFD]

Great thread.

I need to replace my sender and decided to cut the hole.

Stopped by my wrench and asked him his thoughts. Reply went something like this: I've done hundreds over the years. Very easy ... avoid use of sparking tools and have at it.
_________________
1970 Deluxe Sunroof Bay Brilliant Blue/Cloud White
1973.5 911 Targa
2009 MB C300

[hill]

Of course cut a hole. Do it safely and finish it professionally - it'll ease your life and your future owner will thank you.

The orange painted example is superbly done, and there are also bronze maarine vent or fueling access units avaiable at better chandleries (marine supply stores) but they aren't for penny-pinchers.

And if you should like to admire your sender......http://www.newfoundmetals.com/catalog/pg05.html

[lakewils]

To replace Bus Fuel Sending Unit, what is safe to cut hole with? How much clearance is there before one would hit the fuel tank? Have never done this and honestly am concerned about hitting fuel tank. I know not to use a torch of course. Someone said jig saw. Isn't that likely to contact fuel tank?

[Wildthings]

[Krautski]

This thread never disappoints to hit all highs and lows of the bus demographic.
_________________
BUS FOR SALE

[skills@eurocarsplus]

i am going to be forced to do the hole myself. not opposed to it, but the currently available tube senders for the early bays suck...

it to me 5 to get one that works form a vendor here

and, the 5th one didn't work. i go so pissed, i opened it up to find the wire broke loose (in transport perhaps, but the pin was holding the float) so i soldered it back together.

i don't have it in me to waste the better part of a day pulling a bus apart for a fuel sender.
_________________

[geopanoramic]

Good discussion / pros and cons. I had my chance to make sender holes with the tanks out twice now. Just didn't want to hack it (per one population's preference). Some very nice jobs here refinishing the holes. Given poor quality modern replacement parts, I guess the hole is something to do, and do right the first time around.

[Opossum]

[Keith]

Does anyone have a picture of the measurements VW gave for cutting the hole ? It was in one of the factory service books, I believe the orange one.. I only ask for that for others to have.

What I REALLY want a picture of is the part where VW told you to flatten the ends of the ribs and then you used a factory block off plate for the hole. There were pics and measurements of where to flatten the ribs as well as pics of the block off plate and even a part number for it. I have yet to actually see one of these plates but I'd love to have one.

My bus was hacked for the hole when I got it and I had sourced a ribbed section from a donor bus to make a cover from that.
_________________
Formerly known in the forums as "OVALTEEN"

"I firmly believe that some villagers from Botswana could probably build a better road than PennDot."- Splitty

"If you do anything to your car someone will hate on you for it. People absolutely love to complain and find fault with others. Don't let it bother you. Just live and have fun."- Lind

[busdaddy]

[busdaddy]

[skills@eurocarsplus]

[Wildthings]