Oke doke, all fixed. To begin with I found what I think is a repro sender in the tank. I’d like to see an original one as a comparison.
But on to the repair. After removing the hollow rivets and disassembling the unit, I found the problem was with the flexible band that completes the circuit from the wiper to ground. It was broken into four pieces. It was made from .004” thick material and I just happen to have some .004” brass material on the shelf so I just made a new band. The wiper and grounding band are held on the float arm axle with a one-way Pal nut. To remove this I used a small diamond-grinding wheel in the Dremel. Assembling the parts with the new band is a simple straight forward process and a new Pal nut from McMaster Carr finished it off. The one other thing I had to make were the hollow rivets just like the original ones. I made a tool up to spin the heads over in the lathe from 3/16” brass tubing and used the same tool to set the rivets when they were installed back on the unit. I tested the range and it runs from 1.9 ohms to 38.1 ohms. Couple of pics here, take a look.
http://rides.webshots.com/photo/2810310490098611668EngTlM Took it for a ride tonight and the needle was as solid as a rock.
What I save? Bout $60 with the shipping.
Denny Graham
Sandwich, IL
