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  1. #1
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    tips on Safest way to install a Fuel sender into new aluminium tank?

    Hi all,
    looking for advice on fitting a fuel sender into my alloy tanks in my ski boat. I have both a bow and under floor tank and they have never had senders installed so i will have to drill with a hole saw to fit a Weema style sender but im obviously nervous about the hazard of a potential spark and the swarf and crap that will fall into the tank whilst drilling. Does anyone have any tips on the safest way to do this without basically letting a grenade off infront of me and not let any swarf in?

    I have heard of a trick online from a custom auto show where they will hook up a hose to the exhaust of a petrol car and the other end to the inlet of the tank and let it idle for an hour to completely remove the fumes and vapor and this way they are able to weld on it without too much worry.

    keen for thoughts, im aware this is a dangerous task and may not attempt if there is no other simple trick to doing this safely

  2. #2
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    I would use CO2... either from a small welding tank & regulator (which is what I had), "dry ice", or a CO2 fire extinguisher (probably the simplest) to displace the air and vapor in the tank while also cooling the fuel ( -75*C) and condensing any remaining vapor back into liquid. https://www.continentalcarbonic.com/...nks-safer.html

    You can smear grease over the cut line and on the hole saw to catch the filings or use a low pressure air nozzle to blow them around the boat... away from the hole.

    Let's just go ahead and make America great again!

  3. #3
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    I've heard of guys that have to repair diesel slip tanks. Drain fuel, fill with water and weld up holes or cracks.

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