drilling fuel tank?

I have been offerd a good fuel guage/sender unit for the tank in my bobtail which is aluminium

but obviously I have to drill the top to take the sender unit,is this gonna be a good idea? stopping the swarfe goin into the tank seems to be the problem

diesel??

what size hole?? Can't see there been that much swarfe going into the tank as most of it'll fall on floor as ya drilling. Filter on tank pick up should stop it getting into fuel lines. shame it int a steel tank Cos magnet would get it all out.

especially if ya use a strong hoover to suck it up s ya drilling

yeh doozil..

the hole is about 55mm there don't seem to be any filter on the tank

hoover while yer drilling,get yer doris to suck it for ya...

Take it out,empty it and drill it upside down

MPfive said:

Take it out,empty it and drill it upside down

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getting it out could be an issue and it is fookin heavy anorl

Has the tank got any residue, cos the swarf sticks inside the tank and will drive you mad forever more.
Drill upside down wash out then fit a inline pre filter to catch remnants.
Ive learnt above from experience of making a tank and forgetting a hole

pressbrake said:

Has the tank got any residue, cos the swarf sticks inside the tank and will drive you mad forever more.
Drill upside down wash out then fit a inline pre filter to catch remnants.
Ive learnt above from experience of making a tank and forgetting a hole

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getting the tank out would mean removing all racking and shelves from the rear.the tank was made by the previous owner so I guess they didn't think about an aftermarket guage

My friend has a plasma cutter, it's a fantastic bit of kit.
Not sure if its a good idea with fumes from a tank?
Still amazing tool.

This is what I would do .

Drill bit in centre of hole cutter smeared with grease, drill pilot hole then clean swarfe off bit.

Regearse and grease the area that the hole cutter will cut through.

Drill almost through and then put hole cutter away

Finish the last bit of the cut with a Dremmel, the fine bits will get caught in the grease as you go round.

thats what I would do, not what everyone would recomend but I would be happy that almost no bits had got into tank.

shop vac next to hole saw will take care of all the chips

Turn it upside down with a loadall and drill.... Simple

magnet0604 said:

Turn it upside down with a loadall and drill.... Simple

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read post 7 and 9

wiltshire landyman said:

read post 7 and 9

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A loadall forklift

chainsaw chain oil or EP90 drizzled evrywhere on the drill and the tank wiping the swarf away evry few seconds or blow the swarf away with an air line taped to the tank while yer drill it

hoover and a bit of grease for good measure.

johnny curt 1 said:

chainsaw chain oil or EP90 drizzled evrywhere on the drill and the tank wiping the swarf away evry few seconds or blow the swarf away with an air line taped to the tank while yer drill it

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fookin bad enuff the smell of ep90 from outside let alone smearing the **** inside

gonna order the kit.. and reckon its a hoover and grease to trap the swarfe..better not use the wifes dyson tho will have to use henry hoover from the garage

this is the kit ive bought btw

Airworld Solid State Fuel Level Gauge with 24 bendable probe 300373

a couple of really strong magnets on the case right next to where you are drilling, (+ the grease as mentioned) once drilled feel on the inside of the tank and any swarf will be stuck to the inside top by the magnets + all the stuff that comes off the top will go to the magnets too.