can I plug fuel sending unit hole

[DCnj]

can't remove a broken sending unit bolt. tried every thing .unit or gage have not worked  since I bought the boat 2 yr. ago. do u guys think I can plug it with a brass and rubber expansion plug?

[Capt. Bob]

I have two concerns.

First, expansion plugs work best when they contact a large area of the "pipe" to be plugged. The fuel tank is very thin and leaves a minimum of surface area for seating the edge of the plug.

Second, is the rubber material of the plug fuel resistant, especially fuel containing ethanol?

You might want to try and heat the tank around the screw with a heat gun (no open flame) and use a vise grips to turn the remaining screw out.

Good luck.

[Woodeneye]

Try the ATF and Acetone concoction. The internet swears by it!
https://www.youtube.com/watch?v=2WuVBFTzoKc

[DCnj]

Thanks Guys, It a poly tank and has about 3/4 of an inch to seat to. will have to check to see if the rubber is fuel resistant. Bolt broke off flush with tank now so will have to plug it or go with 4 bolts and sealer.

[Woodeneye]

One of these may do the job after a good soaking: http://www.amazon.com/SpeedOut-Damaged-Screw-Extractor-Bolt/dp/B00IRL3WP4/ref=sr_1_1?s=hi&ie=UTF8&qid=1456270396&sr=1-1&keywords=easy+out

[DCnj]

tried screw extractors. just going with 4 bolts and sealent. any recommendations?

[xo4001]

can't remove a broken sending unit bolt. tried every thing .unit or gage have not worked  since I bought the boat 2 yr. ago. do u guys think I can plug it with a brass and rubber expansion plug?

Can you use this http://www.wemausa.com/sensors/adapters.shtml#Underring and mount a regular sender or gauge back inplace
you can drill the broken bolt out and use the under ring to mount the new gauge
good luck

[DCnj]

great. didn't think of a split ring. will check them out