The way I plan to fasten the sending
unit to the tank is by making a five position nut-plate out of 1/8"
thick steel. I scribed
around the gasket that came with the sending unit which acted like a
template and then I'll cut away the center with a hole saw. This
plate will be welded to the inside of the tank when finished. At this
point, the five 8-32 threaded holes have been drilled and tapped.
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I used a belt sander to finish the O.D.
(outside diameter) and then a die grinder to dress-up the I.D. after
using the hole saw. I'll be using button head stainless cap screws
to fasten the sending unit to the tank. Now all I have to do is weld it
in place and to do that, I'll need to get started on cutting out some
sheet metal.
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This is the material that I'm going to
be using for my fuel tank which is .035" thick steel. I sheared the
pieces to the sizes needed and I'm now ready to cut some holes.
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What I'm doing is cutting out one hole
for the fuel sending (bottom) unit and the other is where the filler
neck and gas cap
will be. These holes are 1 5/8" diameter. The line that you see
running from left to right is going to be the transition from the top of
the tank to the radius that will go towards the bottom. I'll also be
adding one more hole for a rollover valve but we'll get to that later.
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