Drilling holes for new level sensor in full fuel tank.

[Chris & Lenore]

When I went to install a new fuel level sensor, I found a surprise when I removed the old unit. Besides two screws being stripped, there are two holes missing - check the pic to see what I mean.

The new mount has a larger set of mounting holes that line up with "good metal", but I need to drill 5 pilot holes foR the screws. Can I drill these 5 small holes with an almost full tank (diesel, not gas)? Aluminum will not spark plus I'll be using a drill extension that places the drill itself above deck (I will be working through a deck access hole).

I think it's just a matter of how to catch the bits of aluminum that fall into the tank as the drill breaks through - or do they even matter given the degree of filtering in a diesel fuel system. Draining the tank can be done but I'm not sure how I would clean out any metal shavings given my only access is via the fuel sensor hole.

I'm sure others have had this type of problem...

Thanks, Chris

 

[Benny17441]

Just drill slow cleaning the shavings as you go before punching through. It is inevitable that you will get some inside the tank but the particles will fall to the bottom and mix with the other junk down there. Should any small particles travel up the fuel pick up it should be strained by the filters. I would not worry about it.

 

[Chris & Lenore]

Good advice. I assume "Motoseal 1 Ultimate Gasket Maker, Grey" by Permatex is still the sealant to use with diesel?

Chris

 

[Fred Villiard]

Chris,

If you put a heavy coat of grease on the area arount where you are drilling and on the bit or tap, that will trap most of the shavings so that you can clean them up.

 

[Ken13559]

Chris,

If you put a heavy coat of grease on the area arount where you are drilling and on the bit or tap, that will trap most of the shavings so that you can clean them up.

Good idea. Don't if I steal this idea ....shamelessly

 

[Ron20324]

Stick some duct tape inside the tank, under the new hole to stop shavings from falling through, and it will block your sender hole also. A shop vac next to the drilling should suck most of the shavings away.

 

[Chris & Lenore]

It went well - actually easy considering I was working through a 6 inch deck plate. Used duct tape under the hole and on top - don't think much (if anything) went in the tank. Thanks again for all the advice.

Chris