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.

 

[the_elder_rocker]

Hi Folks-
Thought I might dredge this one back up. Have a sort-of functioning sender on a SV and ran across this.

https://www.campingworld.com/universal-electric-sending-unit-for-gasoline-312913.html?cq_cmp=590300366&cq_con=1238051177992732&cq_term=&cq_plac=&cq_net=o&cq_plt=gp&gclid=d3c9dcf8505516036f3ab5ad7e9d1296&gclsrc=3p.ds&msclkid=d3c9dcf8505516036f3ab5ad7e9d1296&utm_source=bing&utm_medium=cpc&utm_campaign=%5Badv%3A%20Camping%20World%5D%20%5Bplt%3A%20Bing%5D%20%5Bfun%3A%20Performance%5D%20%5Bini%3A%20Catch%20All%5D%20%5Btgt%3A%20PMAX%5D%20%5Bcou%3A%20US%5D&utm_term=2329177945378486&utm_content=Catch%20All

I'm not sure about the ohm range. Other than that it looks simple enough to adapt and a whole chunk less money. What do you all think?
Thanks-
Mike Burgess
Albert, KS

 

[hartmandm]

Looks to be a Moeller Marine fuel sender unit given its part number. I'm guessing it will be similar to the Dorman sender I analyzed for DanR. The mounting disc diameter might need to be reduced and the holes need to be plugged. The ohm range appears to be the same as the Dorman unit, which is not quite the same as an Alpine sender. The float rod will probably need some adjustment to improve the accuracy of the low end gauge readings. If you sign up to do all that work, the Dorman unit can be found for less money. There also is a Moeller unit designed for 6 to 12 inch deep tanks. That one is a bit cheaper and maybe the float rod length won't need to be shortened.

 

[the_elder_rocker]

Or this-

Marine Boat Electric Universal Fuel Tank Sending Unit - Fits 6" to 12" Deep Gas | eBay

Fits Tank Depths: Designed to fit fuel tanks between 6" and 12" deep. Complete Installation Kit: Includes a gasket and screws for easy installation. Made in the USA: Proudly manufactured in the USA, ensuring top-quality construction and performance.

www.ebay.com

Both have a 33-240 ohm range.

Looks to be a Moeller Marine fuel sender unit given its part number. I'm guessing it will be similar to the Dorman sender I analyzed for DanR. The mounting disc diameter might need to be reduced and the holes need to be plugged. The ohm range appears to be the same as the Dorman unit, which is not quite the same as an Alpine sender. The float rod will probably need some adjustment to improve the accuracy of the low end gauge readings. If you sign up to do all that work, the Dorman unit can be found for less money. There also is a Moeller unit designed for 6 to 12 inch deep tanks. That one is a bit cheaper and maybe the float rod length won't need to be shortened.

Thank you for the reply. It's great to have a deep well of knowledge to draw from. I read the post on the Dorman unit. Lots of info- easy to follow. All things considered, I think I prefer the configuration of the marine unit. Closer to stock and it looks as though it will be easier to remove in the future. The Dormans have gone up- same or a bit more than this one. First I will try to rehab my old one. It was crusty! A couple days soak in PB and disassembled to clean. The windings are loose in the middle on the rheostat(?) section and the reading is wonky from 1/2 -up. I have a really good rheostat plate and top mounting disc from a Spitfire unit that look identical on inspection- just have to be really careful attaching that tiny little wire from the winding. Nothing to lose really except a little shop time- but what's better than shop time anyway?!? Again- thank you!

 

[hartmandm]

A very minimal search and on Amazon I saw the Dorman unit for $25 and the Moeller unit for 6-12 inch tanks for $35.

 

[the_elder_rocker]

A very minimal search and on Amazon I saw the Dorman unit for $25 and the Moeller unit for 6-12 inch tanks for $35.

Wow. Great tip. I just popped on ebay and they were same or more. Amazon irked me with some ugly shipping issues on some tractor parts and I've avoided them since. Maybe I'll break down and look at them some. I guess they do rule the market after all, but I sometimes hold a grudge. Happy New Year!

 

[hartmandm]

Grudges can be good.

 

[the_elder_rocker]

Update- I have fuel readings. The "rheostat" from the Spitfire unit did the trick. Drilled out the rivets on the old winding plate, replaced it with the plate from the Spit ("rheostat") riveted it in and soldered the tiny little wire to the Alpine unit. Plugged it into the wire in the trunk, jumpered the mounting disc to ground, turned on the key and moved the float rod back and forth and voila! Readings! Accurate even! Took a couple of hours but time well spent away from the TV. Keeping the "universal" replacements in mind in case things don't work long term in the real world, though.
Thanks again for the support!
Mike Burgess
Albert., KS