Fuel Pump Cover & sender bracket

[Austin David]

I replaced the internals in my fuel tank.  The plastic hanger is replaced with a printed piece, using PCTG which is stiff and fuel-resistant.  I used 1/2" aluminum bar for the standoff, and made the bright orange mount for my original level sensor / sender.  The sender portion is orange because if it somehow gets loose, I want to be able to find it in the future.

 

Both parts are PCTG, which should be very fuel / heat tolerant, and are easy to print.  The lid portion is pretty thick, lots of walls.  There are two bulkhead fittings for the wires, I could have done one (in retrospect).  I like the symmetry tho, and won't change it unless I have another reason to reprint the mount.  The through-fittings are sealed with permatext fuel gasket stuff, which I determined is extremely fuelproof.

 

The design of the original lid holds a sort of air bubble between the fuel tank and the through fittings; I assumed this was a deliberate feature, to be sure there wasn't an obvious through fitting below the waterline when the tank is full.

 

Because I put the sender standoff on that vertical aluminum brace, I was able to relocate it slightly futher south and can take advantage of the full swing of the sensor.  Experiments pending a dry day, but at "very nearly dry" the gauge sits at the bottom, and adding 2.5g measured it reads just above 1/4.