Rajan Wilcox
Fuel tank floats are used to accurately track the fuel level inside a tank. They are usually made from materials that are resistant to gasoline, such as nylon, PVC, or epoxy. The float is attached to a rod, which is connected to a fuel level sending unit with a printed circuit board. As the fuel level in the tank adjusts, the float moves up and down the rod, opening and closing reed switches in the circuit board to give an accurate reading of the fuel level. In this article, we will discuss the steps involved in making a fuel tank float, including choosing the appropriate materials, designing the float, and assembling it with the fuel level sending unit. We will also explore some common issues and solutions related to fuel tank floats, such as holes in the float or inaccurate readings due to additional weight on the float.
| Characteristics | Values |
|---|---|
| Materials | Nylon, PVC, Plastic, Pill Bottle |
| Float Function | Track the fuel level inside the tank |
| Float Movement | Up and down the rod |
| Float Location | Inside the fuel tank |
| Float Position | On top of the fuel |
| Float Density | Lower than gasoline |
| Float Resistance | Resistant to gasoline |
| Float Cost | $3.27 |
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What You'll Learn
Choose a suitable material
When choosing a suitable material for a fuel tank float, it is important to consider the density and resistance of the material. The float should be made from a material that is resistant to gasoline and has a lower density than gasoline. This will ensure that the float is effective in measuring the fuel level accurately.
One material that has been suggested for fuel tank floats is nylon. Nylon is gas-resistant and has a lower density than gasoline, making it a suitable choice for fuel tank floats. It is also a durable material that can withstand the fuel environment without degrading over time.
Another important consideration is the ease of handling and cost-effectiveness of the material. If you have financial limitations, as in the case of the Baja SAE team, you may want to consider materials that are easy to work with and readily available at a low cost. This could include using pill bottles or PVC boards, which can be cut to size and drilled to fit the fuel tank.
Additionally, the size and shape of the fuel tank should be considered when choosing a material for the float. The float should be designed to fit comfortably inside the tank and be able to move freely as the fuel level changes. This may require customizing the float to fit the specific dimensions of your fuel tank.
It is also essential to ensure that the material chosen for the float is compatible with the fuel type. Different fuels may have varying levels of corrosiveness or reactivity, so it is crucial to select a material that can withstand the specific fuel environment in which it will be placed. This includes considering the chemical composition of the fuel and selecting a float material that is resistant to any potential degradation or corrosion caused by the fuel. By carefully considering these factors, you can choose a suitable material for your fuel tank float that is safe, effective, and durable.
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Ensure it's resistant to gasoline
To ensure that your fuel tank float is resistant to gasoline, you can consider using materials that are known to be gas-resistant. Nylon, for example, is a suitable option as it is gas-resistant and can float in gasoline. This material is similar to what is used in carburetors.
PVC is another option, as one user reported that their PVC fuel float lasted for 20 years before it eroded. However, this material may not be as resistant as nylon and could eventually erode over time.
If you are looking for a temporary solution, ping-pong balls can also be used as a fuel float. This option may not be as durable as nylon or PVC, but it can be effective in a pinch.
It is important to note that gasoline is a strong solvent, so it is essential to keep your fuel tank full or use fuel additives to prevent corrosion and lubrication issues. By keeping the tank full, you ensure that all parts are in contact with the fuel, which helps to prevent corrosion.
Additionally, you can use fuel additives that are designed to protect against corrosion and improve lubrication. These additives can help to maintain the integrity of your fuel tank float and other components, ensuring their longevity.
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Make it lighter than gasoline
To make a fuel tank float, the float must be resistant to gasoline and have a lower density than gasoline. One material that meets these requirements is nylon, which is gas-resistant and floats on gasoline.
Nylon is a suitable material for a fuel tank float due to its low density and resistance to gasoline. It is also relatively easy to handle and work with, making it a practical choice for fabrication.
Another important consideration is the size and shape of the float. It should be designed to fit comfortably inside the fuel tank and allow for smooth movement up and down as the fuel level changes. The float should also have a mechanism to attach it to the fuel pump or a float arm, such as a hole or a cap that can be glued or welded in place.
Additionally, the float should be sealed properly to prevent gasoline from leaking into it. This can be achieved by using epoxy or other suitable sealing materials to create a fully encapsulated float.
By choosing the right material, such as nylon, and considering the design and sealing of the float, you can create a functional and durable fuel tank float that stays buoyant on gasoline.
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Attach it to the fuel pump
The float is a crucial component of a fuel tank, as it accurately tracks the fuel level by working in tandem with the reed switches on the printed circuit board. The float contains magnets that move up and down the rod, automatically opening and closing the reed switches to provide an accurate fuel level reading. The float is usually attached to the fuel pump and sits directly on top of the fuel, moving down as the fuel level decreases.
To attach the float to the fuel pump, you can follow these steps:
Firstly, ensure you have the appropriate materials. The float should be made from a material that is resistant to gasoline and has a lower density than gasoline, such as nylon. The rod, which the float moves up and down on, is typically made from stainless steel, specifically SUS 316, which has high amounts of chromium and nickel and is commonly used in level-sensing technology.
Next, you'll need to connect the fuel level sending unit cables, which are usually made from polyvinyl chloride (PVC). The cables will have two wires, one pink and one black. The pink wire is the ground wire, which should be connected to a common grounding hook-up. The black wire is connected to the gauge hook-up. Ensure these connections are secure and correct, as they provide power to the fuel level sending unit.
Once the wires are connected, you can attach the float to the rod, ensuring it moves smoothly and freely up and down. The rod should be attached to the head of the fuel level sending unit, providing an even surface for the float to move and giving an accurate reading of the fuel level.
Finally, test the setup by powering on the gauge. The reading should correlate with the liquid level inside the tank, as indicated by the float's position. Ensure that the float moves freely and accurately reflects the fuel level, even when the liquid inside the tank sloshes around.
By following these steps, you can successfully attach the float to the fuel pump, allowing for accurate fuel level readings in your fuel tank.
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Test it works accurately
When troubleshooting fuel gauge issues, it is recommended to start by checking the fuel tank's sender unit as it is the most common cause of incorrect readings. The sender unit is used to measure the amount of fuel in the tank and communicate the fuel level to the gauge on the vehicle dashboard.
- Check if the sending unit is receiving power from the gauge. The reading at the sending unit will be less than the input voltage at the gauge.
- Verify the sending unit's ground wire. Ensure that it is properly grounded to a common ground or to the negative terminal of the battery.
- Disconnect the sender wires at the sending unit and connect them to an ohmmeter or multimeter. Set the signal to resistance.
- Take measurements of the sender at empty and full positions. This can be done by either draining and refilling the tank or manually operating the float by hand after removing the sending unit from the tank.
- Compare the measurements with the expected values for an accurate fuel tank float.
- If the measurements do not match the expected values, there may be a problem with the float or other components of the fuel gauge system.
It is also important to note that fuel level sensors are not always accurate, especially in dynamic driving environments. External factors such as turning, accelerating, or driving on hilly terrain can affect the accuracy of the fuel gauge readings. Additionally, keeping the fuel tank below a certain level can cause problems for the float and other components due to the solvent nature of gasoline.
As a verification step, you can also try the following methods to track fuel usage:
- Pump the tank dry and measure how much fuel it takes to fill it to a certain point.
- Track the number of laps and the amount of fuel required to return to the starting fuel level.
- Measure the weight of fuel cans used during refuelling.
By following these steps and considering the limitations of fuel level sensors, you can accurately test and verify the functionality of your fuel tank float.
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Frequently asked questions
A fuel tank float is a floating plastic piece that sits inside the fuel tank and floats on top of the fuel. It works with the reed switches in the printed circuit board to accurately track the fuel level inside the tank.
The purpose of a fuel tank float is to sense how full the tank is. As the fuel level in the tank adjusts, so does the float. This information is then used to determine the fuel level.
Materials used to make a fuel tank float should be resistant to gasoline and have a lower density than gasoline. Nylon is a suitable material as it is gas-resistant and floats.
A fuel tank float works by opening and closing reed switches in the printed circuit board. The float contains magnets that move up and down the rod, opening and closing the reed switches automatically. This movement allows the float to determine the fuel level without delay.
