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Enjoy.
The most important thing I found was that the biggest contact problem is NOT where the wiper contacts the resistance wire, but in the ground contact. If I connect my ohmmeter from the connector - where the wire harness connects to the sender - and the long float arm, I get reliable and steady readings. But if I move the ohmmeter lead to the housing, where the system ground connection normally is made, no matter how solid and clean a connection I make to the housing, the readings are very erratic. This tells me that the problem is where and how the wiper makes contact to the housing.
Jeff, I think if you had a more accurate meter and measured just between terminal and case as the arm moves you'd see that the resistance goes from about 10 or 20 ohms to about 250 Ohms. 28 Ohms should read Full, and under 10 Ohms should peg the needle. 250 ohms should read 0 , and 1000 or more should read off scale below zero, about same as with the key OFF.
Nice to know we can get to the sender without removing the tank.
Tom