pics of the tool i made
as promised, this is the basic tool I made to remove and install the fuel tank sender unit. You need a welding machine to make it.
I tried the screwdriver technique also, but it only distorted my lips. Envisioning a situation where the lips were fully waisted, i decided to go the long but sure route.
I thought I welded on 2 tabs, but appearently I made 3 tabs. The long one actually engages 2 lips of the sender unit.
To get the tabs in the correct position, just lay tabs on the fuel tank sender unit against the lips of the sender unit. Then put the base plate on top of it, and mark the relative positions. Move the pieces to your workbench and weld there.
Don't weld on top of the tank even if you think it is empty, or we'll have one forum member less.....
basically, only 2 tabs will engage the lips, as the accurracy to position the 3 or 4 tabs isn't good enough to make sure they are all load bearing. But it never hurts to try. The more lips are pushed, the more the force is spread, thus giving less distortion.....
But maybe i'm overthinking it here.
Erik.