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Bay Window Fuel Gauge Access

Discussion in ''How To' & 'Handy Hints'' started by ttmck, Mar 18, 2007.

  1. ttmck

    ttmck Super Moderator Staff Member

    Messages:
    2,733
    Location:
    Hallett Cove STH AUS
    Pictures now for access panel at long last .
    I went to my local wreckers for mitsubishi and obtained from under the rear seat of any TE - TW magna a fuel sender unit panel as you can see from the photos it works a treat and does not look out of place it saves having to pull the engine out then the fuel tank to replace the sender unit
    This was previously posted a link to a guy whom i think went a little over the top but if you have time yep do it his way , but this takes all of 15 mins to change a tank unit * the bustop sells tank units * contact his reverence [roy] if you need one .
    All you need is the dimensions for cutting count the ribs from my photos , i was standing at the rear of the kombi looking towards the front .
    A jig saw , cordless drill is handy
    A magna fuel sender cover all of $ 5.00 bucks if you get on well with your wrecker they will prob give you one
    A few screw drivers , and pk screws
    A compass to draw a circle , permant marking pen .
    I fitted foam under the magna panel to make is seal due to the floor ribs
    drill 4 holes 1/8 inch drill bit

    To remove the sender once the hole is cut disconnect the two wires attached ,rotate the locking ring , remove the sender , replace it with the new one , replace the sender seal , you may need to vaseline the new sealing ring . refit the locking plate connect the wires
    fit the magna plate along with some foam .
    NO MORE RUNNING OUT OF FUEL ON DARK WINTER NIGHTS !!

    http://www.specialpatrolgroup.co.uk/spooky/access/access.html
    Dimensions and the long way to do it

    [​IMG]
    The magna panel fitted looking from the back


    [​IMG]
    The magna panel looking from above from the rear rock and roll seat
    Dimensions 157 mm x 157 mm
     
    Last edited: Mar 23, 2007
  2. ttmck

    ttmck Super Moderator Staff Member

    Messages:
    2,733
    Location:
    Hallett Cove STH AUS
    If any one needs an access panel fitted in adelaide give me a shout , i have some spare covers
     
  3. Aging Surfie

    Aging Surfie New Member

    Messages:
    82
    Location:
    Waikiki Western Australia
    Thats mate. I have a bodgey job done by previous owner. Was going to buy a boat hatch cover at cost of $55-00. Of to the wreckers now.

    Cheers for that. Great stuff. Reckon this should be a sticky.

    Deano
     
  4. brookie

    brookie Guest

    It is a "sticky" and a good one!
     
  5. hedgehogxpress

    hedgehogxpress New Member

    Messages:
    19
    Location:
    Melbourne
    How much do oyu think i would be up for paying someone to this kind of job? At volkspowere where i've been for myfirst service they said it would cost up to 500 dollars :S
     
  6. brookie

    brookie Guest

    The way ttmck does it about $50.
    C'mon Team Melbourne to the rescue:)
     
  7. One of the best time saving mods you could ever do!!!
     
  8. kommodius

    kommodius Active Member

    For a 15 minute job that's only $2000.00/hour, quite reasonable. Unless they have to supply parts in which case it's down to
    $1900.00/hour!! .......................Bargain!!


    Do it yourself mate! $100.00 for the sender, $15.00 for a pack of jigsaw blades and 15 minutes later a working fuel gauge.

    Ray & da Boyz
     
  9. ttmck

    ttmck Super Moderator Staff Member

    Messages:
    2,733
    Location:
    Hallett Cove STH AUS
    i want a piece of that hourly rate , send it my way hahahaha !
    seriously if you sweet talk your local wrecker put on a sad face and say its for my kombi you will get it cheep or next to nothing . my local sent me a heep so if you cant get one and i doubt that will be the case just pm me .
    ray is right roy the bus stop has sender units to sell im picking mine up in canberra . im just waiting for the sender to pack up . forward planning . at this stage it will happen i know it will .

    i bet ray you feel alot safer than carrying that 20 litre jerry just waiting to konk out
     
  10. kommodius

    kommodius Active Member

    Oh, I still carry that Tom!! I'm addicted to the fumes now!

    Ray & da Boyz
     
  11. Dingostrategy

    Dingostrategy Active Member

    Messages:
    4,322
    Location:
    SW Vic ++
    Yes, but will it fix my kombi??

    Hi all,

    Brilliant idea. watch me drill too far and -KABOOM- but that's not my point...

    My guage 'works' but has 'shifted' to the right, meaning it moves from right of F to the middle. Is this what we mean when we say the sender's cactus, or would that be diagnosed by a totally dead needle?

    If the former, I'm sorted and will do this mod. If the latter, any clues about what my problem is.

    $2k. Bloody hell. Now I've heard it all! What next, 60,000 for a split! Oh, wait, that's already happened.
     
  12. Doc

    Doc Well-Known Member

    Messages:
    2,902
    Location:
    Gunnedah
    Hi guys
    I changed the fuel gauge in my daughters 1974 Kombi this afternoon and there were a few incidents

    This is the diagram that Tom referenced earlier (linked)
    [​IMG]

    For a 1974 bay my suggestion is that you make it 800 from the lip or better still as close to the rear seat as you can but you will need to leave enough room to seal it afterwards.

    I could get at the sender unit but it was awkward.

    Lessons Learn't
    1) If using a jig saw make sure you use a fine tooth metal saw.
    2) Make sure the depth of the saw is not too deep. I started out with a Ryobi unit which was inherited from my father in law ....... This worked fine until the blade clamp shattered ..... I then bought a Bosch and the blade will hit the fuel tank by about 1/4 of an inch.
    3) Don't make the hole where the diagram says move it towards the front of the car.
    4) Clean as much crud as you can after you have opened it up
    [​IMG]
    [​IMG]
     
  13. Doc

    Doc Well-Known Member

    Messages:
    2,902
    Location:
    Gunnedah
    Here is the new sender
    [​IMG]

    Important Lesson

    1.)Have the tank less than 1/2 full otherwise you will have to put the sender in 180 degrees the other way
    2.) Use Rubber Grease on your O ring
    3.) Because of the new O ring the gauge was near impossible to turn So use a big screwdriver as a lever and the top of your hole as the fulcrum it will go in.
    4.) If you do put it in 180 degrees in the wrong direction make sure you wires are the correct way round!
    [​IMG]
    I made my cover our of some old Kombi corrugated
    [​IMG]

    I would normally silastic and seal it up but as I am completely anal about most things when I am out of fuel I will probably rotate the gauge and the close it up with silastic as well as self tappers
    [​IMG]
     
  14. MattB

    MattB New Member

    Messages:
    501
    Location:
    Melbourne
    Looking good there Doc :) My fuel sender has been broken since I've got my Kombi, I've just calculated the number of kms I get from a tank and make sure I check the odo :p I'm not too keen on cutting a hole in my Kombi in case I screw it up, so I'm just waiting until I drop the engine and will pop a new one in then. Your work is very neat.
     
  15. emby

    emby Active Member

    Messages:
    2,006
    Location:
    Wights Mountain, QLD
    Doc, did you follow the instructions on the sender kit and completely drain the tank before you inserted the new unit?

    I bought one the other day after ordering those CV boots from CIP1 to pad out the order a bit to make the shipping worthwhile, but haven't got around to installing it yet.
     
  16. Doc

    Doc Well-Known Member

    Messages:
    2,902
    Location:
    Gunnedah
    What instructions ?
    I got the sender unit and a good luck and a warning not to bend it!
     
  17. emby

    emby Active Member

    Messages:
    2,006
    Location:
    Wights Mountain, QLD
    I could scan and send them to you, but it looks like you managed without them.

    What happened to RTFM?
     
  18. Doc

    Doc Well-Known Member

    Messages:
    2,902
    Location:
    Gunnedah
    RTFM?

    I'd love to see the instructions
    Scan them over some time
     
  19. Marty

    Marty Active Member

    Messages:
    2,290
    Location:
    Sunny Melbourne
    i really should have had the sender replace when i had the engine out. still kicking myself about that one!
     
  20. emby

    emby Active Member

    Messages:
    2,006
    Location:
    Wights Mountain, QLD
    Doc,

    You've got mail ;)

    And I've just found out how to use the new printer as a scanner too :cool: How's about that without any RTFM. (Read the ........ Manual):lol:
     

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