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repair of fuel gauge float & bonnet release (ideas for rookies)medium lo

To: triumphs@autox.team.net
Subject: repair of fuel gauge float & bonnet release (ideas for rookies)medium long
From: Davgil@aol.com
Date: Tue, 11 Jan 2000 13:23:48 EST
Listers,
Recently, I made mention of problems with my fuel gauge sending unit float 
and bonnet release cable.  Thanks to T.R. Householder, John Rossi, Randall 
Young, Neal Grotenhuis and Ray James for their ideas and suggestions.  In 
repairing the fuel gauge float, I learned two techniques that may be of value 
to other newbies.  The float that I had was approximately 85% full of 
gasoline, and the leak was almost a pinhole size leak.  I discovered that 
while holding the float in my hand, the heat from my hand would cause the air 
inside to expand and force a small amount of fuel out of the float.  The 
solution to the problem of getting the fuel out of the float was to heat 
sequentially heat and cool the float (I used a hair dryer - Thanks Randall) 
to gradually eliminate the fuel.  This process becomes more efficient as the 
volume of fuel is reduced.  Of course, if you use an ignition free heat 
source in a well-ventilated area your chances of success are greatly 
improved.  After a good cleaning, I coated the float with "Hot Fuel Proof 
Dope" that I obtained from a local hobby shop (again thanks Randall).  
Several coats of the lacquer-type paint sealed the float.  To ensure that 
there would not be a temperature change that would blow out the new seal, I 
immersed the repaired float in hot water to see if the expanded pressure 
would blow out the seal.  My concern was twofold.  First, I did not want the 
float to get warm and blow out the plug, so to speak.  Also, I did not want 
the float to be cooled and draw the plug and any gasoline in which the float 
may have been submerged into the float.  I also tried to clean the dope off 
of the float with gasoline to ensure that it was impervious to the gasoline, 
and I think that this is good stuff.  The remainder was simple to complete.  
The usual problems of reinstalling the sender, running out of gas on the way 
to the station, etc.
On another note, John Rossi had a great suggestion about my broken 
bonnet-release cable, that is to install an emergency release.  Ray James had 
a good idea about shortening the cable by replacing the T-handle with a loop 
of the cable to create a loop handle, covered with spare fuel line to make it 
a little more comfortable to pull.  I have decided to combine the two ideas 
and replace my existing cable to maintain originality and to use the broken 
handled cable to fabricate an emergency release cable that I will run up to 
my grill.  This one will have a looped handle.  Boy, the ideas you get from 
the real pros on this list are great and make owning and driving these cars 
even more of a pleasure.
Best regards and happy motoring to all.
David Gill
76 TR6 with operating fuel gauge and soon to be modified with emergency 
bonnet release.

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