Fuel sender install

I’ve been waiting on some more tank sealer so I could install the fuel senders. UPS claimed they delivered it on Wednesday, but it didn’t show up. On Thursday it turned up with another package, so I was able to install the senders tonight.

I took time doing prep work; scuffing the surfaces, cleaning the surfaces, checking that my multi-meter was working, checking that the screws installed in the nutplates, checking that I had the right size Allen Key, etc. Finally I was ready to mix the sealant and get started.

I had one wing on the bench and one in the stand. The wing in the stand was in a slightly awkward position, as the stand itself was interfering with the placing of the sender into the hole in the end of the tank. With a bit of adjustment I got it to work ok, and that’s the wing I started with. In hindsight, I should have started with the easier wing, so I could build some experience. Oh well.

On the right wing, I could have used more sealant. I’m sure I got a good seal in the end, but I don’t think I hit the goal of 0.7mm between sender and rib. This space is to allow easier removal of the sender in the case of future tank maintenance. With a slight gap, a blade can get in there to cut the sealant. I have some gap there, but I think it’s less than desired. It’s also tricky to get an even torque on the screws around the flange of the sender, it’s probably not exactly square. I checked that the plate is grounded, and it seems fine.

Then it was onto the easier-to-access left wing. This was quick, clean, and came out great. I used more sealer, and ended up with a nice even bulge of seal around the sender flange. Looks to be just right. Hopefully if I have to do maintenance on tanks, it’ll be the left one!

Next up I’ll be installing the tank drain fitting, then pressure testing the tanks for leaks.