Fuel level sending unit question

[guitbiking]

I have a fuel level sending unit that has wires broken off at the connectors at the base of the unit inside of the tank. I'm not concerned with losing the fuel level function (can use odometer like other bikes). But, I need to power the fuel pump. The ground wire is still intact, but the power to the fuel pump wire is not only broken off, but there is no nib to solder it to.
 It would seem that the base plate could be drilled such that the two fuel pump wires could be routed through it using a fuel safe grommet and sealer. Much like the little plastic original connector accomplishes.
I'm thinking other applications of in-tank fuel pumps must accomplish getting the wires to it in a similar fashion, without including a 200 dollar fuel level attachment :(
Before I do an lengthy search, has anybody done this type of repair? Thanks!

[Laitch]

Before I do an lengthy search, has anybody done this type of repair?

Somebody must have done it to have created a market for fuel-tight grommets. Give it a go and show others a path out of this condition.

[guitbiking]

I came up with this item that might fit the bill. https://www.summitracing.com/parts/abt-cfd-504/overview/. Usually for the top of a fuel cell. But I was thinking of running PTFE insulated wires through it and putting a little JB Weld Steel Stik on the connector for good measure.

The other option would be to run a bulkhead stud through. Then connect wires to the outside and the inside of the stud. Probably only one for + and use the existing ground post on the sending unit plate. As I doubt there is room for two studs in the plate without weakening it.

Any thoughts on the legitimacy of my thinking? It would be about a 50 dollar fix.

[volador]

I came up with this item that might fit the bill. https://www.summitracing.com/parts/abt-cfd-504/overview/. Usually for the top of a fuel cell. But I was thinking of running PTFE insulated wires through it and putting a little JB Weld Steel Stik on the connector for good measure.

The other option would be to run a bulkhead stud through. Then connect wires to the outside and the inside of the stud. Probably only one for + and use the existing ground post on the sending unit plate. As I doubt there is room for two studs in the plate without weakening it.

Any thoughts on the legitimacy of my thinking? It would be about a 50 dollar fix.

BADA BOOM
pm sent

[guitbiking]

Bada Boom, like in Boom?


https://media3.giphy.com/media/oe33xf3B50fsc/giphy.webp?cid=790b761120d9549842a68e71cd194e354f5e139080f28e56&rid=giphy.webp

[Laitch]

Any thoughts on the legitimacy of my thinking? It would be about a 50 dollar fix.

Your thinking seems reasonably dispassionate and analytical. There's always this, too. It would likely give you a pump connection you could strengthen; function of the fuel level sender would still be questionable.

[guitbiking]

All for naught. I was able to melt the plastic around the post enough to solder a wire to it. I was also able to clamp the wire so that there is no tension on the solder.
Happy trails to you.

[Laitch]

All for naught.

Which was the all and which was the naught.

[The Mighty Gryphon]

So you're telling us your repair didn't work?

[Chaos]

No, I think he's saying posting here was an exercise in futility.

[Laitch]

I think he's saying posting here was an exercise in futility.

Probably. I think his innate genius will carry the day wherever he goes.

[guitbiking]

Holy crap! I just meant that I was able to melt the plastic on the original part such that I could attach the wires and solve the problem without having to do a work around as I thought was my only option. I reached out for help and was encouraged to try it.
 Perhaps a poor choice of wording on my part in the follow-up, by trying to be brief. But did it really seem that I was being arrogant or offensive?
I don't often ask questions, because I do extensive research on this and several other sites before asking. I am grateful for all of the helpful information.

[Scott]

Holy crap! I just meant that I was able to melt the plastic on the original part such that I could attach the wires and solve the problem without having to do a work around as I thought was my only option. I reached out for help and was encouraged to try it.
 Perhaps a poor choice of wording on my part in the follow-up, by trying to be brief. But did it really seem that I was being arrogant or offensive?
I don't often ask questions, because I do extensive research on this and several other sites before asking. I am grateful for all of the helpful information.

I understood what you did and you also were able to take the strain off the repaired joint as well. Good job in this throw away and buy new culture.

[The Mighty Gryphon]

Your wording led me to think the repair wasn't ultimately successful.  Very glad to hear it worked well. 

Is it possible to post a photo of what you did?  I have a tank connector with a similar issue and would like to try your repair.

[guitbiking]

It is under a gasoline filled tank at this point. I will try to illustrate with a found photo. [img]
fuel sender fix.jpg (43.97 kB . 544x576 - viewed 555 times)[img].
The metal post continues down into the plastic nib, the green line. (Actually it is the wire on the backside, but looks the same.)
I melted the nib with the solder iron until I had enough metal showing to solder to. I then ran the wire through the old float mechanism and pinched the wire with the tab, red line.
A bit of a hack, but it did the job.

[Laitch]

Thanks for the illustration.

[Scott]

I did the same sort of thing on my xt500d, about five years ago on the rectifier diode, I guess it's fixed.

[The Mighty Gryphon]

Nice job!

[Chaos]

Holy crap! I just meant that I was able to melt the plastic on the original part such that I could attach the wires and solve the problem without having to do a work around as I thought was my only option. I reached out for help and was encouraged to try it.
 Perhaps a poor choice of wording on my part in the follow-up, by trying to be brief. But did it really seem that I was being arrogant or offensive?
I don't often ask questions, because I do extensive research on this and several other sites before asking. I am grateful for all of the helpful information.

Don't take it personally. If we're not out riding we're sitting around making obtuse remarks online.  Glad you got your dilemma fixed!

[Past-my-Prime]

Hey I understood "All for Naught"!

It means "All the drama for no big deal" which implies that after the help, you were able to find your way through.

Good job mate!

[volador]

Hey I understood "All for Naught"!

It means "All the drama for no big deal" which implies that after the help, you were able to find your way through.

Good job mate!

Surprisingly you did not mention "splines"

[Past-my-Prime]

"splines splines everywhere the splines,
do this don't do that"

Sorry, back to your usual programming. I've been into the rum and eggnog this chilly evening.