Sylvie Willis
Installing a fuel level sender in a spun aluminium fuel tank requires careful attention to safety and technical details. Before beginning, it is crucial to ensure the tank is empty and free from any fuel fumes, as gasoline is highly flammable. The installation process involves replacing the existing sender, if present, by unscrewing the screws from the mount and aligning the sender lead hole with the tank lead hole. The length of the sending unit should be measured or determined to ensure proper clearance, preventing malfunction and tank damage. The gasket, included in a gasket mounting kit, should be slid over the down tube, and the screw patterns aligned. The level sending unit is then secured to the tank by tightening the screws in a star-shaped pattern, being careful not to over-tighten. Finally, a leak test is conducted to ensure the unit is properly installed.
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What You'll Learn
- Wiring colours: black and pink wires connect to the negative bus and gauge respectively
- Sender length: order a sender 1/2 shorter than the tank's height
- Tank coating: use three coats of white-tinted epoxy to prevent corrosion
- Tank sealing: seal around the hatch to prevent water ingress and corrosion
- Installation: secure the level sending unit by tightening screws in a star-shaped pattern
Wiring colours: black and pink wires connect to the negative bus and gauge respectively
When installing a fuel level sender in a spun aluminium fuel tank, it is important to take the necessary safety precautions. Gasoline is highly flammable, so ensure the tank area is free from sparks, flames, and power tools that could create sparks.
Before beginning the installation, determine the proper sending unit length for your tank by measuring from the inside bottom to the outside top of the tank. Maintain a minimum clearance of 1" between the tank bottom and the float retaining collar to prevent malfunction, tank damage, and voiding the warranty.
Now, let's focus on the wiring colours: the black and pink wires. The black wire from the sending unit should be connected to the gauge hook-up. If your gauge has colour-coded hook-ups, maintain this coding when connecting the wires. Ensure that the connections are tight and secure.
Turn on the power to the level sending unit and gauge to test the setup. Adjust the float and observe the gauge. If the gauge reading correlates with the position of the float, the level sending unit and gauge are functioning properly.
Additionally, the pink wire is likely connected to the negative bus. It is important to verify the wiring diagram or schematic for your specific application to confirm the wiring colours and connections.
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Sender length: order a sender 1/2 shorter than the tank's height
When installing a fuel level sender in a spun aluminium fuel tank, it is important to consider the length of the sender relative to the height of the tank. The recommended length for a fuel sender is about 1" to 2" (25 to 50 mm) shorter than the height of the tank. This clearance allows the tank to flex or move without damaging the sending unit or the tank itself. A minimum of 1" (25 mm) clearance between the bottom of the sender and the bottom of the tank is generally advised, with some sources specifying that metal tanks require at least 25 mm of clearance, while plastic tanks should have 50 mm or more.
To determine the proper sending unit length for your tank, you can measure from the inside bottom to the outside top of the tank. This measurement will guide you in ordering a sender that is slightly shorter than the tank's height. It is important to maintain the recommended clearance to prevent malfunction, tank damage, and to avoid voiding the warranty of the unit.
When ordering a fuel level sender, it is crucial to consider the application and environment in which it will be used. If the application involves high vibrations or harsh conditions, you may need to incorporate stabilizing elements such as a casing or spring. Additionally, consider the location of the fuel tank and the available space for mounting the unit. If there are space constraints, a side-mounted unit might be more suitable.
Before installing the fuel level sender, ensure that the tank is empty and free from fuel and fumes. Follow the manufacturer's instructions for the installation process, including aligning the sender lead hole with the tank lead hole and securing the unit with mounting screws using a star-shaped pattern. It is important not to over-tighten the screws to avoid weakening the seal and causing potential leakage.
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Tank coating: use three coats of white-tinted epoxy to prevent corrosion
Aluminium fuel tanks are susceptible to corrosion, especially in marine environments. To prevent this, it is recommended to coat the tank with a protective layer of epoxy.
Firstly, it is important to prepare the tank surface by sanding and cleaning it. This removes any existing corrosion and creates a smooth surface for the epoxy to adhere to. It is also crucial to wear personal protective equipment, such as a paint suit, rubber gloves, eye protection, and a respirator, during the preparation and coating process. Ensure that the work area is well-ventilated.
For the coating process, a high-quality epoxy specifically designed for aluminium, such as Pettit Marine Paint's AlumaProtect two-part aluminium epoxy primer, is recommended. This epoxy provides maximum corrosion control and protection against the elements. Mix the two parts of the epoxy thoroughly in a 1-to-1 ratio and let the mixture stand for the recommended time, which can vary depending on the temperature.
Apply a thin coat of the epoxy mixture to the tank using a solvent-resistant roller tray and a 4-inch foam roller. Allow the first coat to dry completely, which typically takes around four hours or longer at cooler temperatures.
Once the first coat is dry, apply a second thin coat of epoxy in the same manner. This second coat ensures thorough coverage and maximum protection.
Finally, to complete the three-coat system, apply a topcoat in the colour of your choice. White-tinted epoxy is an option that will provide a bright and aesthetically pleasing finish. Allow the topcoat to dry completely, following the manufacturer's instructions, before using the fuel tank.
This three-coat epoxy system will provide a durable, corrosion-resistant, and airtight finish to your aluminium fuel tank, helping to extend its lifespan and maintain its functionality.
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Tank sealing: seal around the hatch to prevent water ingress and corrosion
Tank sealing is essential to prevent water ingress and corrosion, which can lead to clogged fuel filters and engine failure. To seal around the hatch of your spun aluminum fuel tank, you can follow these steps and recommendations:
First, it's important to understand the common causes of water ingress. Water can enter the fuel tank through the fill cap or due to condensation inside the tank. Regularly inspecting and cleaning the fuel tank at least annually can help prevent the build-up of condensation and contaminants.
When sealing the hatch, the primary goal is to create an effective barrier that prevents water from entering the tank. One common method is to use a gasket, which is a material that forms a seal between the hatch and the tank. Gasket materials can vary, and you may need to experiment to find the right one for your application. For example, you can try rubber gasket material in different thicknesses and hardness, but be aware that this may not always provide a successful seal.
Another option is to use a gasket maker product, such as Permatex Gasket Maker, which has a version impervious to fuels. This product is easy to apply and sets quickly, providing a durable seal. However, keep in mind that using this type of product may require periodic removal of the hatch for maintenance or reapplication.
Additionally, you can reinforce the hatch and hatch opening to prevent warping, which can lead to leaks. This can be achieved by fabricating and welding steel rings in-situ or drilling and tapping holes in the top of the fuel tank to attach additional metal parts.
Finally, when reinstalling the inspection hatch, consider using a fuel-resistant sealant, such as Permatex® PermaShield® Fuel Resistant Gasket Dressing & Flange Sealant, to create a tight seal between the hatch and the flange. Alternatively, a clear silicone sealant, such as GE Silicone II Kitchen and Bath, can also be used, but ensure it contains a biocide to prevent the growth of contaminants.
By following these steps and recommendations, you can effectively seal your spun aluminum fuel tank, preventing water ingress and corrosion, and ensuring the reliable operation of your engine.
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Installation: secure the level sending unit by tightening screws in a star-shaped pattern
Installing a fuel level sender in a spun aluminium fuel tank requires careful attention to safety and a methodical approach. Here is a detailed, step-by-step guide to securing the level sending unit by tightening screws in a star-shaped pattern:
Firstly, ensure the tank is empty and free from any fuel or fumes. This is a critical step to mitigate the risk of combustion. Next, align the sender lead hole with the tank lead hole, ensuring they match. The gasket should also be aligned with the down tube, and the 5-hole screw pattern should fit flush against the underside of the mounting plate. The screw hole pattern is not symmetrical, so there is only one way to ensure proper alignment.
Now, position the level sending unit above the tank, ensuring the screw hole pattern in the mounting plate aligns with the hole pattern at the top of the tank. Once the sending unit is in position, begin tightening the screws in a star-shaped pattern. It is important not to over-tighten the screws, as this can weaken the seal and reduce the service life of the gasket. Excessive torque can cause the gasket to compress or pinch, leading to potential leakage.
After securing the level sending unit, a leak test is necessary to ensure a proper installation. Pressurize the tank to 3 PSI and inspect for bubbles using soapy water around the seal. If bubbles are present, it indicates that the screws are not tight enough and require further tightening.
Additionally, you can conduct a functional test by turning on the power to the level sending unit and gauge. Adjust the float and observe the gauge reading. If the reading corresponds to the position of the float, the unit and gauge are functioning correctly.
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Frequently asked questions
First, ensure your tank does not have any mounting tabs. Then, coat your tank with three coats of white-tinted West epoxy, using West's aluminium etching kit. Next, connect the wires from your fuel sender (usually pink and black) to the wires from your fuel gauge.
If your fuel sender is electronic and isolated from the tank, it will likely have a plastic body. In this case, connect the black sender wire to the negative bus, and the pink wire to the gauge.
Measure from the inside bottom to the outside top of the tank. The sender should be 1" shorter than this measurement.
Adjust the float and pay attention to the gauge. If the gauge has a reading that correlates to the position of the float, the level sending unit is functioning properly.
