Fuel tank sender-Vw T2

[hippywitch72]

Has anybody cut a hole in the top of a camper rear shelf/bulkhead to change the fuel tank sender, rather than take the engine/tank out? Is it feasible?

 

[70-CA-Panel]

I don’t weld but wouldn’t you need to take the tank out to weld a hatch in? Same probably if you used a grinder to cut the hole. It’s been a good few years since I’ve taken the engine and tank out, but it really isn’t that big of a deal.
Gets you to look at everything closely again anyway which is a good thing .

 

[67panel]

You could cut the hole with a nibbler .

 

[70-CA-Panel]

You could cut the hole with a nibbler .

Very true and then use panel adhesive to glue in an extended panel hatch.

I’ve got to earth my fuel Sender again after doing a tank restoration and discovering that the earth wasn’t good enough after everything was back in again , so the full removal is on my list at some point again, but I won’t cut a hatch in.

 

[sparkywig]

Butty's Bits are about to make a removable fuel sender access panel.

 

[trinketpimp]

Did mine with a large hole saw and made a panel (square) that goes over the top. Given that I have bought 3 sender units it's been a winner.....

 

[ozziedog]

I like the sound of the Buttys bits one! Cutting a hole shouldn’t be a mahoosive issue especially if you used a straight edge that would also limit your grinder penetration but I’d check smelly fuel pipes first. Then simply glue a patch a bit bigger over it. It’s not like you’re gonna be in here on a daily or even a weekly basis, nothing a long bladed craft knife couldn’t cope with.

Ozziedog,,,,,,,,, I’d check on the buttys bits one first.

 

[fatgaz]

Has anybody cut a hole in the top of a camper rear shelf/bulkhead to change the fuel tank sender, rather than take the engine/tank out? Is it feasible?

I cut a whole to access when I was renovating my bus. I had access to a donor bus so cut out a larger section then used Rivnuts to secure. Access now is easy if I ever need to go in again.

 

[fallingoffalot]

I bought one a few years ago from Custom & Commercial I think. It's still in it's packet. I saw a scan of some official looking instructions at some point, shows you what measurements to take to get it central. Here you go.. https://www.thesamba.com/vw/forum/viewtopic.php?p=7472371
There are also many YouTubes on it.

 

[dubselector]

A H Schofields sell a panel which you can either weld on, or I made a rubber gasket for and used self tapers to screw it down. The panel was quite generous so trimmed it down to just cover hole with a margin for the gasket. Did have the engine out and firewall off at the time so I could see where to cut

 

[dubselector]

Or if your van is a crossover then Hayburner stock a removable option

 

[Madjon]

US based but these are nice quality.

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[hippywitch72]

Thanks everyone for all your posts - most useful. Will let you know the results of our attempt! (Hopefully no fire extinguishers involved).

 

[Thekeg]

Has anybody cut a hole in the top of a camper rear shelf/bulkhead to change the fuel tank sender, rather than take the engine/tank out? Is it feasible?

Hayburner make one and I did it last year, really straight forward and you can join their free VW 1/4 year magazine.

 

[Thedragon74]

Hayburner make one and I did it last year, really straight forward and you can join their free VW 1/4 year magazine.

Hi,
Yes! I have done this. I did mine when I put a new engine in my 69 panel van. I took the tank out and replaced it with a new one.
If you want to do it with the tank in, I would drill 4 corners and cut out with a jigsaw. I got a cover for it from ALANHSCHOFIELD. There’s pictures of it on Instagram oldvolksbus if you want to have a look.

 

[Thekeg]

Hayburner make one and I did it last year, really straight forward and you can join their free VW 1/4 year magazine.