Fuel sender access hole, to do or not to do? |
To do |
|
55% |
[ 37 ] |
Not to do |
|
44% |
[ 30 ] |
|
Total Votes : 67 |
|
Author |
Message |
mikewire Samba Member
Joined: March 22, 2010 Posts: 802 Location: San Antonio, TX
|
Posted: Mon Aug 17, 2020 12:11 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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!
Link
_________________ -Mike
@countdowngarage
@bigskyeuro
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC swap
1965 VW Beetle Deluxe Bahama Blue |
|
Back to top |
|
|
Kiwi1966 Samba Member
Joined: August 18, 2009 Posts: 168 Location: Ohoka New Zealand
|
Posted: Wed Mar 10, 2021 1:52 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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
|
|
Back to top |
|
|
skills@eurocarsplus Samba Peckerhead
Joined: January 01, 2007 Posts: 16803 Location: sticksville, ct.
|
Posted: Wed Mar 10, 2021 9:12 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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 _________________
gprudenciop wrote: |
my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese....... |
Jake Raby wrote: |
Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public. |
Brian wrote: |
Also the fact that people are agreeing with Skills, it's a turn of events for samba history |
|
|
Back to top |
|
|
Cuccuzze Samba Member
Joined: June 26, 2013 Posts: 67 Location: Sharpsburg, GA
|
Posted: Thu Mar 25, 2021 7:12 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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
|
|
[/quote] _________________ 1971 VW westy
My generation made girls take home ec and sewing. I really wished they let us learned cars! |
|
Back to top |
|
|
Abscate Samba Member
Joined: October 05, 2014 Posts: 22568 Location: NYC/Upstate/ROW
|
Posted: Fri Mar 26, 2021 2:33 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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
_________________ .ssS! |
|
Back to top |
|
|
Wildthings Samba Member
Joined: March 13, 2005 Posts: 50261
|
Posted: Fri Mar 26, 2021 6:37 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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 |
|
Back to top |
|
|
aeromech Samba Member
Joined: January 24, 2006 Posts: 16926 Location: San Diego, California
|
Posted: Fri Mar 26, 2021 8:13 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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 _________________ Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound |
|
Back to top |
|
|
mikewire Samba Member
Joined: March 22, 2010 Posts: 802 Location: San Antonio, TX
|
Posted: Fri Mar 26, 2021 8:27 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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. _________________ -Mike
@countdowngarage
@bigskyeuro
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC swap
1965 VW Beetle Deluxe Bahama Blue |
|
Back to top |
|
|
Cuccuzze Samba Member
Joined: June 26, 2013 Posts: 67 Location: Sharpsburg, GA
|
Posted: Sun Mar 28, 2021 12:48 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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!) 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. _________________ 1971 VW westy
My generation made girls take home ec and sewing. I really wished they let us learned cars! |
|
Back to top |
|
|
cmonSTART Samba Member
Joined: July 15, 2014 Posts: 1915 Location: NH
|
Posted: Sun Mar 28, 2021 12:55 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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.) _________________ '78 Bus 2.0FI
de K1IGS |
|
Back to top |
|
|
aeromech Samba Member
Joined: January 24, 2006 Posts: 16926 Location: San Diego, California
|
Posted: Sun Mar 28, 2021 1:35 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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. _________________ Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound |
|
Back to top |
|
|
Cuccuzze Samba Member
Joined: June 26, 2013 Posts: 67 Location: Sharpsburg, GA
|
Posted: Sun Mar 28, 2021 3:11 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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. |
_________________ 1971 VW westy
My generation made girls take home ec and sewing. I really wished they let us learned cars! |
|
Back to top |
|
|
Wildthings Samba Member
Joined: March 13, 2005 Posts: 50261
|
Posted: Sun Mar 28, 2021 4:14 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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.
Last edited by Wildthings on Sun Mar 28, 2021 7:44 pm; edited 1 time in total |
|
Back to top |
|
|
aeromech Samba Member
Joined: January 24, 2006 Posts: 16926 Location: San Diego, California
|
Posted: Sun Mar 28, 2021 6:20 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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 _________________ Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound |
|
Back to top |
|
|
Abscate Samba Member
Joined: October 05, 2014 Posts: 22568 Location: NYC/Upstate/ROW
|
Posted: Mon Mar 29, 2021 3:06 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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!) 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)
_________________ .ssS! |
|
Back to top |
|
|
Ghunt Samba Member
Joined: November 25, 2022 Posts: 26 Location: Havertown, Pennsylvania
|
Posted: Mon Aug 07, 2023 6:35 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
Anyone have hole locating dimensions for a 1969 bus? Thank you. |
|
Back to top |
|
|
aeromech Samba Member
Joined: January 24, 2006 Posts: 16926 Location: San Diego, California
|
Posted: Tue Aug 08, 2023 2:32 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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
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 _________________ Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound |
|
Back to top |
|
|
SGKent Samba Member
Joined: October 30, 2007 Posts: 41031 Location: Citrus Heights CA (Near Sacramento)
|
Posted: Tue Aug 08, 2023 3:53 pm Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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. _________________ “Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin |
|
Back to top |
|
|
NASkeet Samba Member
Joined: April 29, 2006 Posts: 2947 Location: South Benfleet, Essex, UK
|
Posted: Wed Aug 09, 2023 6:26 am Post subject: Re: Fuel sender access hole, to do or not to do? |
|
|
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!?! Reviews are to be found in past issues of Motor Caravan Magazine and the Caravan & Motorhome Club magazine. _________________ Regards.
Nigel A. Skeet
Independent tutor (semi-retired) of mathematics, physics, technology & engineering for secondary, tertiary, further & higher education.
Much modified, RHD 1973 VW "1600" Type 2 Westfalia Continental campervan, with the World's only decent, cross-over-arm, SWF pantograph rear-window wiper
Onetime member, plus former Technical Editor & Editor of Transporter Talk magazine
Volkswagen Type 2 Owners' Club (Great Britain)
http://www.vwt2oc.net |
|
Back to top |
|
|
sodbuster Samba Member
Joined: August 08, 2004 Posts: 1082 Location: wherever my baywindow takes me.
|
Posted: Wed Aug 09, 2023 9:13 am Post subject: |
|
|
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. |
|
Back to top |
|
|
|