Fuel Sending Unit Repair for C2 Needed

[Ronald L.]

Re: Fuel Sending Unit Repair for C2 Needed

Those new screws are the problem
the threads are horrible turned up metal and cut the o rings

I had to pass a die over them so they would thread in
all new

what kind of sealant?

the stick kneadable epoxy did not work

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

Ron,

I used Seal All.

James

James,
What did you use as a fuel tank sealer, this hot epoxy?

Got a zip coupe neck that is leaking out the bolt threads ...

[Mark F.]

Re: Fuel Sending Unit Repair for C2 Needed

I also tried John Wolf and he told me about Tri Star Radiator LLC in North Pitcher NY. He said he was not recommending them but heard of them. I asked around on the CF and as I remember some people commenting it was long time to repair and expensive, but other than that nothing negative so I sent my 66 leaking but accurate fuel sender to them on Jan 3rd of this year. (The reproduction I got from the corvette parts place kept blowing fuses and was wildly inaccurate although the ohms checked ok.) Tri Star Radiator told me it would be at around 3 months but your thread gave me a reminder to drop them a friendly email and inquire about the status. I will send a follow up post when I get it back and get it installed, but may be a while as thinking about changing the gas tank out also. Good luck. Mark

Sent my fuel sender in to TriStarr LLC in January of this year. Was returned in mid May Cost $229 plus shipping. Was planning to change out the fuel tank in June/July so waited until then to put it in. Using the quanta gas tank, O ring and retaining ring with the original rebuilt fuel sender it went in way easier than the fight I had with the reproduction fuel sender, O ring and retaining ring in the original tank. Anyway the fuel sender is in now about 2 weeks, not leaking and indicating accurately. TriStarr asked if I wanted it painted, originally said no, but TriStar does not make it look like new, so I said go ahead and repaint. Maybe a mistake?

Providing this thing does not leak, I would recommend TriStarr.

[Harry S.]

Re: Fuel Sending Unit Repair for C2 Needed

I forgot I had this NOS unit. Pictures FYI.

IMG_4723.jpg

IMG_4724.jpg

[Victor P.]

Re: Fuel Sending Unit Repair for C2 Needed

Hello. Finally got my original sending unit back from Bob's Speedometer. Apx $600 also. PRICEY but what looks like a good job. Used original NOS GM "O ring" (A BIG THANK YOU to the gentleman who sent me the link. I lost his email), and I used fuel resistant sealer also and no leaks after a week and seven gallons. Five gallons shows a little over an eighth of a tank which is consistent with a couple of other cars with original sending units. Negatives besides price; They did the typical promise of six weeks and took five months. I called them after four months and they said they would mail it that Thursday, two days later. It took a month after that. Cheers. V

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

Victor,

So you are telling me that you filled the tank with 5 gallons of gas and the gauge reads between empty and 1/4 tank???

James

Hello. Finally got my original sending unit back from Bob's Speedometer. Apx $600 also. PRICEY but what looks like a good job. Used original NOS GM "O ring" (A BIG THANK YOU to the gentleman who sent me the link. I lost his email), and I used fuel resistant sealer also and no leaks after a week and seven gallons. Five gallons shows a little over an eighth of a tank which is consistent with a couple of other cars with original sending units. Negatives besides price; They did the typical promise of six weeks and took five months. I called them after four months and they said they would mail it that Thursday, two days later. It took a month after that. Cheers. V

[Victor P.]

Re: Fuel Sending Unit Repair for C2 Needed

Yes. My other cars do the same

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

Well, then I guess I don't have a leg to stand on to ask them to rework the sending unit I sent them to repair which reads the same as yours. My only concern is that when bench testing the sending unit for the last time it would only read 83 ohms when the float was raised as high as it can go. It was at 0 (zero) when the float was as low as it could go. I still think it should read more accurate than what it does. I guess it's better that it reads higher than it actually is rather than lower. I haven't filled it to 3/4 full (15 gallons) and completely full (20 gallons) to see if the readings stay linear.

At 10 gallons of gas my gauge reads just a little higher than half way between 1/4 and 1/2 full. Sorry, didn't have my phone locked so the picture is this way.

James

Yes. My other cars do the same

[Richard M.]

Re: Fuel Sending Unit Repair for C2 Needed

Most senders I've self restored typically never get to 90 ohms, usually around 85 ohms.

The wirewound resistor is riveted in and isn't placed accurately in the housing and impossible to move around, unless you drill out rivets and stake in new rivets. And trying to bend the riveted in beryllium copper wiper arm is dangerous as it's very brittle.

Here's one I redid on a '67 years back. 86 ohms.

It's a busy photo laden thread so it'll take a while for photos to download.

Preview.....
P9160062.jpg

P9160064.jpg

P9160040.jpg

P9160058.jpg

Rich

[Joseph S.]

Re: Fuel Sending Unit Repair for C2 Needed

In most of the 63-67 cars I have owned (that would be many) the fuel gauge is not linear. They stay on Full for quite a while, blast through the center section then have about 2 to 3 gallons in them when on empty.

[Terry M.]

Re: Fuel Sending Unit Repair for C2 Needed

Joe,
That's a great point that you raise. When I think about it, most, if not all, the cars I have owned stay on full for a good bit. Once the guage starts to move it seems to go down at a regular rate. When it gets closer to empty, seems to slow a bit. Thanks for your insight.

Terry

[Victor P.]

Re: Fuel Sending Unit Repair for C2 Needed

That is the same spot that mine read at 9 gallons. I think that is GM's thinking so people do not run out of gas. When it hits zero they have apx 3-4 gallons left but will stop at a gas station. I remember the old Dick Van Dyke show when VanDyke bought in Italian sports car and at the end of the show he sold it because he ran out of gas because when the gas gauge hit zero it actually was zero. I think that all the American car manufacturers do this.

[Dan B.]

Re: Fuel Sending Unit Repair for C2 Needed

Most senders I've self restored typically never get to 90 ohms, usually around 85 ohms.

The wirewound resistor is riveted in and isn't placed accurately in the housing and impossible to move around, unless you drill out rivets and stake in new rivets. And trying to bend the riveted in beryllium copper wiper arm is dangerous as it's very brittle.

Here's one I redid on a '67 years back. 86 ohms.

It's a busy photo laden thread so it'll take a while for photos to download.

Preview.....
[ATTACH=CONFIG]118637[/ATTACH]

[ATTACH=CONFIG]118638[/ATTACH]

[ATTACH=CONFIG]118639[/ATTACH]

[ATTACH=CONFIG]118640[/ATTACH]

Rich

Rich, Were you able to get that sender working with just a cleaning? I was looking at your other thread and it did not seem like you had to do any wiring repairs. Many of the "restored" senders I see seem to have heavier upgraded outside wires.

[Richard M.]

Re: Fuel Sending Unit Repair for C2 Needed

Rich, Were you able to get that sender working with just a cleaning? I was looking at your other thread and it did not seem like you had to do any wiring repairs. Many of the "restored" senders I see seem to have heavier upgraded outside wires.

Dan that was a working sender but after replacing it with a K&B repro, we decided to get the car judged at the Florida Regional.

So I refurbished the original and reinstalled it.

Its been fine ever since.

Rich

[Dan B.]

Re: Fuel Sending Unit Repair for C2 Needed

Dan that was a working sender but after replacing it with a K&B repro, we decided to get the car judged at the Florida Regional.

So I refurbished the original and reinstalled it.

Its been fine ever since.

Rich

Thanks for clarifying, I know you have done some extraordinary repair and rebuild work. Rewiring that sender resistor winding is definitely above my pay grade