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AT805
Samba Member
Joined: June 04, 2023
Posts: 25
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 Posted: Thu Feb 08, 2024 1:32 pm Post subject: Fuel sending unit port |
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Hi guys, I wanted to share my experience with my fuel sending unit..
Once I determined the issue wasn't the gauge or wiring (lots of info around on that), I bought the new unit. From what I read the new ones fail regularly so I wanted a permanent access port.
I drilled a small hole about where the unit was supposed to be, just enough to peer down there with a light. Mine was actually closer to the front of the bus and more to the right than the diagrams I was finding, who know why.
I decided to go marine deck plate and went with a 5" stainless one ($60 on Amazon). I was surprised how much room (at least 2") there was between the floor and the top of the tank, so once I traced out around the new plate my jig saw made clean, quick work of the sheet metal.
I had to angle out the old unit but plenty of room. The new one didn't come with a gasket but the old one was plyable and felt good reusing it. Dropped in the new one, tested, screwed down the plate and caulked around it.. done deal!
Was a pretty easy job once I got past the idea of cutting the hole, may have done it differently if the new units lasted. But overall happy with the look and function.
Hope this helps someone else
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The engine's in the back? ..curious neighbor |
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KTPhil 
Samba Member
Joined: April 06, 2006
Posts: 34003
Location: Conejo Valley, CA
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| Posted: Thu Feb 08, 2024 1:54 pm Post subject: Re: Fuel sending unit port |
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Nice work!
I started a thread or two about this issue, and there are others. Lots of good ideas; too bad VW didn't include this from the factory! |
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mikedjames
Samba Member
Joined: July 02, 2012
Posts: 2736
Location: Hamble, Hampshire, UK
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| Posted: Fri Feb 09, 2024 12:13 am Post subject: Re: Fuel sending unit port |
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It was probably a good call to reuse the old gasket.
My new sender gasket leaked when I filled the tank. It needed a thicker gasket that I cut out of some cork and rubber gasket sheet.
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Ancient vehicles and vessels
1974 VW T2 : Devon Eurovette camper with 1641 DP T1 engine, Progressive carb, full flow oil cooler, EDIS crank timed ignition.
Engine 1: 40k miles (rocker shaft clip fell off), Engine 2: 30k miles (rebuild, dropped valve). Engine 3: a JK Preservation Parts "new" engine, aluminium case: 26k miles: new top end.
Gearbox rebuild 2021 by Bears.
1979 Westerly GK24 24 foot racer/cruiser yacht Forethought of Gosport.
1973 wooden Pacer sailing dinghy |
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AT805
Samba Member
Joined: June 04, 2023
Posts: 25
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| Posted: Sat Feb 17, 2024 9:03 am Post subject: Re: Fuel sending unit port |
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| KTPhil wrote: |
Nice work!
I started a thread or two about this issue, and there are others. Lots of good ideas; too bad VW didn't include this from the factory! |
Thanks! Im sure I read your posts about it, just wanted to add some info I didn't remember seeing before like sender location not always being where it's supposed to be 🤣 and how much room there is between floor and top of tank. I also wasn't sure what kind of port to install, wanted to show the deck plate as a really good option too
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