Sending unit inaccessible / drill tank in place?

[kdiddle]

So - as it goes, my fuel gauge failed. Thinking it would be an easy in/out, I pulled the floor panel from my boat and found not only is the sending unit completely inaccessible due to being partially under the rear deck, the access hole for the tank is entirely too small to remove the tank to replace the sending unit.

I suppose I could go without a gas gauge, but I really, really don't like the idea due to how much we use the boat. Short of hacking my floor to get to the sending unit, does anyone know if its possible to drill a new sending unit hole and install an entirely new sending unit? I don't like the idea of drilling into an in place tank, but with it being plastic, I figured it might be ok.

BTW I tested the gauge by grounding my pink wire, so it definitely appears to be a failure of my sending unit.

 

[kdiddle]

Here's a closer pic of the sending unit location

 

[harringtondav]

I replaced my sending unit while recarpeting. It was under the tank access panel. But I had to remove a lot of upholstery to get to the panel. So I cut in a floor access cover in case I need to get in there again.

So consider one of these.

 

[Scott Danforth]

as indicated above, install an access hatch.

 

[kdiddle]

An access hole with removable cap is already on the panel, but its oddly nowhere near where the sending unit falls. How can I add a second access hole when the sending unit falls on the seam between the floor panel and deck?

 

[Chris1956]

The sender unit is quite thin, compared with the cover plate. Perhaps having an access close to the sender will allow you to pull it out at an angle.

On a related rant. It appears that the top cap on your boat was installed after the fuel tank was installed. So the tank cannot be removed in one piece, and the sender cannot be changed easily. I am seeing more and more of this type of construction.

My neighbor's Boston Whaler 27 footer had the boarding ladder installed before the top cap was installed. One of the mounting bolts broke,and there is no way to get to the inside to install a nut on a new bolt. My other neighbor has a newish deck boat. We could not install a new cleat, without cutting a hole on the inside of the top cap.

sorry for the rant...

 

[Bondo]

Here's a closer pic of the sending unit location

Ayuh,...... Take the screws out with a right-angled screwdriver, 'n then you can probably get the sender out,.....

 

[dingbat]

Have you actually tried to remove it?

You would need a right angle screwdriver, but otherwise you might be surprised. You only have a very small diameter tube on the end of the mounting plate to get out the hole

 

[kdiddle]

yep Chris, the tank was definitely installed before the cap, which is why I can't pull it out. Someone was definitely not thinking about future serviceability.

I suppose I can notch out around the sending unit and just leave it open as it (see pic below). I really hate to cut into a perfectly good deck with no way to put it back, but this falls under the rear bench seat so not only is it out of sight, but it also isn't in a load bearing spot where folks will be standing on it.

 

[kdiddle]

Bondo/Dingbat, no I haven't tried. The deck is very close to the screws (probably 1"), so not even sure there is enough room for the screws to be completely backed out. But I guess I'll give it a shot and see before I hack my deck...

 

[harringtondav]

Deck butchery wouldn't be the worst thing, considering where it would be located. The access panel looks like it will still be well supported. The cut out will be hidden beneath your bench cushions. Use some white duct tape to tack the cut out back in place. I doubt anyone but you will notice.

 

[AShipShow]

Also looks like hex head bolts holding it in... should be able to get em with a standard box end wrench

 

[kdiddle]

Quick follow up here since you all were nice enough to chime in on my issue. Yep Mad, since they were hex bolts, they were surprisingly easy to remove. it was crazy tough but I was finally able fish the sending unit out without cutting my floor. It turns out it wasn't a float/arm type, it was a vertical tube with a mag float that rides vertically and the float was nearly too large to wiggle out the hole.

I found and ordered a similar replacement - so hopefully I'll be back on the water in no time. Thanks all!