Tank Half Empty or Half Full

[Silver Creek Sunbeam]

Greetings Sunbeamers...

I am interested to hear if any of you have found a Fuel Sending Unit that is for any reason preferable to the original.

I am in need of a replacement. I know Classic Sunbeam has the stock replacement but I thought I'd ask about alternatives. I found some kind of ambiguous posts from years ago but nothing solid.

I know there are excellent write ups on rebuilding/making a better ground on the old one and also a testing procedure and I read both of those but due to my injury (still recovering) and available time right now...I need plug and play.

As always...your input is appreciated.

 

[hartmandm]

Tod,

Back in 2019, I didn't think there were any drop-in replacement fuel senders available for series 3 to 5. DanR was looking for a fuel sender for one of his cars. I fiddled with an aftermarket fuel sender, a Dorman 55818, to see if I could get something workable. I believe I worked out something that is usable, but it has a couple of drawbacks:
1. The fuel gauge readings are off a bit throughout the range from fuel tank full to empty.
2. The diameter of the top disc of the sender is a bit too large to fit in the fuel tank sender opening. Its size needs a bit of reduction. Picture from DanR attached showing the size issue. The top disc also has some holes that need to be sealed.

If you are curious, I've attached my analysis and mods to the Dorman sender. I don't know if DanR has actually used the sender yet.

Personally I'd go with a drop-in replacement sender. They are pricey, but they should save a lot of time and effort that is needed to modify an aftermarket sender.

Mike

 

[Silver Creek Sunbeam]

Thanks Mike...I'll take a look.
I figure if there is an alternate replacement that you, Dan, or a few other engineering types on the forum that come to mind would have found it by now. Lol

If nothing easy and accurate pops up tonight, I will take your advice and order a stock replacement in the morning.

Your input is always appreciated...

 

[DanR]

Tod, for what it is worth Mike did a great job of analyzing the pros and cons on the replacement unit for me.

I did get the lip to fit very well by grinding it to match the stock one. It will be going in my Red GT V6 shortly. Then I will be able tell more about its' functional compatibility with the Alpine tanks and fuel gauge.

An original tank unit that functions as designed, meets your pocketbook is first choice. The reason I was interested in some sort of "replacement" was they are extremely rare and expensive. I do not know of a company making an original replacement as of now.

I have more pictures I will upload shortly.

 

[Aladin Sane]

I will be watching this with interest as I need a sender for my VDO fuel gauge.

 

[DanR]

The attached pictures are provided to show a possible replacement sender for out Sunbeam Alpines.

The PICS are in sequences that may help explain what I did from the time I received the new unit until it was ready for installation.

In a couple pictures you will see a Nut that can be removed for disassembly. I did the disassembly so I could have the "mount plate reduced in size (diameter). You can get an accurate measurement and grind to fir the stock fuel sender hole in the tank or have it machined in a lathe. Just be cautious not to destroy the plate.

Another note to consider is to weld up the holes in the plate and smooth for an even snug fit in the tank rim on a new gasket.

The measurements of the sender can easily be adjusted to function inside the stock Alpine tank.

Mike Hartman was very instrumental in providing the accuracy readings for the sender as applicable to the stock fuel gauge. I have not yet installed my "new" sender. It is for the Red GT V6 currently being put back together. Hopefully I can soon attest to the functional capabilities as worthy the effort for a replacement. New or good functional stock ones are rare and when located they are extremely expensive.

NOTE; Mike posted his PDF in the write-up on the Dorman sender on post #2 above.

Mike

Please ask questions or make comments that may help in this regard. Keep'em-on-the-Road,

 

[belmateo]

I have two good used ones if anybody here needs one.

 

[hartmandm]

Dan,

I included a PDF of my write-up on the Dorman sender on post #2 above.

Mike

 

[Alpine 1789]

In a couple pictures you will see a Nut that can be removed for disassembly. I did the disassembly so I could have the "mount plate reduced in size (diameter). You can get an accurate measurement and grind to fir the stock fuel sender hole in the tank or have it machined in a lathe. Just be cautious not to destroy the plate.

Would it be easier to just make a new plate? If calibration details can be worked out, it seems like having a bunch of properly sized plates made would make this a pretty simple replacement.