I finished the fuel sender this week. It ended up being quite a fiddly and time consuming project, with components being sourced from a few different places. Everything has to be fuel resistant: hose, wires, terminals and heat shrink insulation.
Sender from the '88 model tank, in it's unmodified state:
I used a Ford Territory in tank pump, with 3/8" submersible Gates hose and AN fittings. Wiring is Tefzel insulated, with Viton heatshrink over the solder joins.
I think the pump will be up to the task, but if not, there is a high output Walbro pump available that is virtually a direct replacement for the pump in this setup.
I have a few of the Territory pumps and I considered running a pair in parallel, but by the time I got all the required fittings etc. it was going to be cheaper to buy a Walbro, so I decided to stick with a single pump.
It was also getting pretty crowded on the sender bulkhead just with the fittings and terminals required for the single pump.
Components, and pump mounting detail. The plastic sleeve that holds the pump is from an early '80's 240 sender, cut so it expands to fit the larger diameter pump, and clamped.
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The wiring, bulkhead terminals and hose is from EFI Hardware in Melbourne, the AN fittings are from ebay, and other fittings are from Pirtek etc.
Finished assembly:
Next step is to get the tank mounted up and plumbed in.