Mechanical fuel sender

Get a sheet of gasket material from your car parts dealers. Usually a sheet about A4 size for $4-$5 . There are various thicknesses. Got a hole punch for screw holes?. Bit of a fiddle but a set of finger nail scissors helps. Tell the missus ( or girlfriend) you,ve no idea why they are a little blunt..

Usually a

a hole punch

scissors helps.

a little

Hi John - thanks for the input.

What I have, however, is a leak at the rubber boot that goes around the actuator arm, just below where the gauge cable attaches. I know RTV wont hold up. I'm thinking maybe a thin (i.e. still flexible) coat of PRC/Pro Seal (aircraft fuel tank sealant)

My worry is that, if it's too stiff, it'll just tear the sest of the boot.

Chris

Hylomar can tolerate gasoline.

It seems that you are having problems with your fuel sender, more precisely, the leaking rubber boot. A common solution to this problem includes replacing the malfunctioning rubber boot or by using a stronger and better quality boot that will last longer when fuel is in contact. There are instances where by detailing the sender, a fuel-safe sealant, or gasket maker, made for the automotive industry in particular has been applied, which has ended up in the individuals successfully preventing the fluid from leaking. If you are afraid that plastic sender's usage might cause damage, it would be worth trying to consider sturdier, quality guaranteed, or certified substitutes or alternatives from the aftermarket. You may also try connecting with forums or groups that dedicate to your car's make and model, as they, most, probably have more relevant information as well as specific aftermarket products, which are not that known. I wish these ideas help you prevent fuel leaks and get your system to run smoothly again!