Topic: Autopsy And Anatomy Of A Fuel Sender -

[jwc66k]

Thanks Bob. I follow this approach - “The difficult we do immediately; the impossible takes a little longer”. It sort of rubbed off my father onto me. We both had one shortcoming, too many projects.
Jim

[DM_1964]

Super effort there Jim and a never say die attitude goes a long way in this restoration game. Well done! 

[midlife]

Thanks Bob. I follow this approach - “The difficult we do immediately; the impossible takes a little longer”. It sort of rubbed off my father onto me. We both had one shortcoming, too many projects.
Jim

That, and "I think I can, I think I can, I think I can..." and "I won't give up.  I won't give up.  I won't give up."

Stubbornness can be both a virtue and a vice. 

[jwc66k]

Stubbornness can be both a virtue and a vice.

Wives and kids?
Jim

[xr7g428]

Just found this thread.  I rebuild these professionally. When the wiper arm fails I solder in a replacement to the top of the horse-shoe.  The actual contact is a brass half sphere. (think half of a BB).  It has to be the correct length.  I cut the new piece from copper / brass alloy sheets.

The next time I do one I will do a few pictures.  The senders pictured can all be saved.  The most lethal thing is as you expect: rust through.  I can fix a few pin holes, and even line the straight parts with thin wall hard brass tube if needed but there are limits.

I am very happy to explain what I do but you have to have a very steady hand, good magnification, and exceptional soldering skills.  I learned jewellery and watch repair as a kid and some of those skills and tools come in handy.

I got into this so I could make the low fuel sender used on cars with the Convenience Control Panel option work properly.  I have been doing a number of Mustang and other senders for folks that like to keep their cars original.

https://desertclassicparts.com/fuel-sending-unit-rebuilding-service/