Installing a fuel sender/gauge, questions

James80 · 06-13-2009, 12:45 PM

My boat has never had a fuel gauge so I have always relied on a dip stick. I would like to install either a mechanical unit with the gauge on top (I can see the front of the tank under the consol) or a normal one with a gauge on the consol.

My problem is that since it never had a unit a hole has to be drilled in the tank. How is the best way to go about this. Should we drain the tank and purge with inert gas or should we drain and fill with water? I don't really like the idea of drill somthing that was full of fuel.

alex n · 06-15-2009, 07:51 PM

If the tank is aluminum, use a brand new hole saw and lubricate constantly with wd 40 as you drill , should go right through without creating any heat. If the tank is empty shoot a co2 extinguisher in there and you'll be good to go

jawz12 · 06-15-2009, 08:00 PM

well...
if there's no sender in the tank,and the tank has never been drilled from the start,i would not install a sender...most small boat tanks are less than 3/16" thick,the area where the sender is put,usually,this area is doubled up in material,this assures the screws for the sender have enough material to bite into...i reccomend you leave well enough alone...

drilling holes in a tank...first,never and i mean ever use electrical tools,that includes cordless battery powered tools,all of these will emit a spark,sparks and vapors do not play well together...use pnuematic tools only...use a little common sense here...

James80 · 06-15-2009, 09:21 PM

Thanks for the responses guys.

The tank in fibreglass. I was thinking of using a manual hand drill, I would not dream of using a power tool anywhere near it.

Jimmy, I pretty sure the tank is thicker than 3/16" but the drilling still has me very nervous (even with a hand drill). Also your not the first person who has said don't touch it.

I think it's a dipstick for now and maybe I'll get a floscan and work backwards instead.

06-15-2009, 07:51 PM	#2
alex n Got fish Join Date: Apr 2007 Posts: 196 Credits: 1,756.1 Boat: Dragonfly 36 Jersey Cape Best Catch: winner 07 Beach Haven White Marlin Invitational	If the tank is aluminum, use a brand new hole saw and lubricate constantly with wd 40 as you drill , should go right through without creating any heat. If the tank is empty shoot a co2 extinguisher in there and you'll be good to go Last edited by alex n; 06-15-2009 at 07:53 PM.

06-15-2009, 09:21 PM	#4
James80 Got fish Join Date: Jan 2007 Location: Trinidad Posts: 170 Credits: 1,758.6 Boat: 23ft Hustler Home Port: IPOA	Thanks for the responses guys. The tank in fibreglass. I was thinking of using a manual hand drill, I would not dream of using a power tool anywhere near it. Jimmy, I pretty sure the tank is thicker than 3/16" but the drilling still has me very nervous (even with a hand drill). Also your not the first person who has said don't touch it. I think it's a dipstick for now and maybe I'll get a floscan and work backwards instead. Last edited by James80; 06-15-2009 at 09:27 PM.

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06-15-2009, 08:00 PM	#3
jawz12 I think Admin is going to let me have this space Join Date: Jul 2005 Location: cape may nj Posts: 1,568 Credits: 4,105.5 Boat: 31 bertram Home Port: cape may nj Best Catch: my dog jawz... Occupation: marine repair shop owner	well... if there's no sender in the tank,and the tank has never been drilled from the start,i would not install a sender...most small boat tanks are less than 3/16" thick,the area where the sender is put,usually,this area is doubled up in material,this assures the screws for the sender have enough material to bite into...i reccomend you leave well enough alone... drilling holes in a tank...first,never and i mean ever use electrical tools,that includes cordless battery powered tools,all of these will emit a spark,sparks and vapors do not play well together...use pnuematic tools only...use a little common sense here...