The new fuel sender has arrived from Craddocks in the UK. Time to see how much fuel is in the tank.

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New and old.

 

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It’s a shame the float is plastic. I could have changed it over but a fellow Land Rover enthusiast has offered to repair the original item so I’ll keep all the parts together. I like the rubber buffer on the new float though, it prevents it knocking (irritatingly) on the top / bottom of the tank at high and low tide.

 

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Rheostats side by side

 

First thing to do was to check the new sender actually works before fitting. To do this a resistance test is done on the rheostat.

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With the float set in the “empty” position a resistance of 34 Ohms is recored

 

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… and the corresponding reading for a full tank is 82 Ohms. These figures aren’t required for any sort of calibration, they simply prove the unit works correctly

 

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But before final fitment, I jury-rigged the unit to earth and connected the negative wire. With the circuit complete, the gauge should work…

 

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… which it did 🙂

 

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Oddly, when the float is set to the empty position, the tank will still read as being 1/4 full. Best keep an eye on that.

 

Time to fit everything back together…

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The original screws were used with some new stainless steel flat and spring washers. I also cleaned the heads of the screws on a piece of wet and dry

 

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Gasket in place and float going in at an angle

 

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On reconsideration, I applied some sealant to both sides of the gasket… just incase.

 

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Sender fitted, sealed in place and cable attached

 

Time to put the cover plate on. I decided not to use the 6 nuts and bolts as they were a pain to get out due to the proximity to the top of the tank. I wanted to have better access so some spire screws were used. These can be unscrewed (as the name suggests) from outside of the seat box… much more convenient.

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Ready for the cover

 

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First of all the redundant holes need to be filled to keep things tidy

 

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A 9mm rubber grommet in each hole sorted this problem

 

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Frame is drilled front and rear, cleats tapped into place and two spire screws offered up

 

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Repeat on the rear of the frame, drill matching holes in the cover and screw down.

 

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Cubby box, seat base and floor mat back in place

 

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Job done…