the current fuel sender in my car screws into a female plate that is then screwed into the ali tank.

However, the female to the tank screws have been stripped, meaning that you cannot get a good seal to the tank, meaing that it leaks when full.

Does anyne have any bright ideas, that do not involve fabrication?

Cheers
Craig

If they were tapped into the 2mm aluminium of the tank I'm not surprised they've stripped.

Best solution is to used a tapped C ring designed for the job - assuming you can find one with the right PCD for your adaptor.

Saw some on a site the other day - I'll have a look around my www history.

Edit:
This shows the kind of thing, but for fuel caps not sensors (might be the same PCD if you're very lucky). It's a C shape so you can manipulate it in through the hole (couldn't do that if it were fully round obviously).

http://www.demon-tweeks.co.uk/products/ProductDetail.asp?cls=MSPORT&pcode=MOCRIN3

I'll keep looking - bugging me now I can't find it.

Edit2:
The other technique (a little more hackish) I've heard about is to drill out the holes you've got and put in bolts (heads in the tank) with a blob of epoxy on each one to keep it in place while you gently put the female over them and put nuts on from the top. If you make the bolts over-long you can hold them in pliers while you nip them up, or rely on the epoxy holding them and use the right length. Need to be careful they don't drop into the tank while you're getting the nuts on though

[Edited on 5/6/09 by iank]

Thanks for that, I have been looking for a solution for ages. Will look into this further. If you come up with any other ideas, pelase let me know.

Cheers
Craig

For the locost solution, make a C-ring.
I used a piece of copper-faced PCB, drilled clearance holes and soldered brass nuts on the copper/underside.