Leaderboard

Hey guys, Got this all figured out- all good info above. I ended up going with a Ø3" 1/8" thick Viton disc that I was able to get from McMaster: Gasket Material Disc, Chemical-Resistant Viton® Fluoroelastomer, 3" Diameter, 1/8" Thick | McMaster-Carr Matched up pretty well with the diameter and thickness of the old gasket, and you don't have to try to cut a perfect circle out of a sheet with an exacto. (wow I remembered how to use photobucket- blast from the past in some super old albums) I used an exacto and some hollow punches to recreate the hole pattern and the center opening for the fuel send unit (far from perfect) Cleaned up the fuel sending unit flange the best I could Aaaaannnddd... was still leaking. So, I noticed that the little G10 (maybe?) board where the leads are soldered in was rusted good all around, and probably the original source of the leak. Take the sending unit in and out a few times, agitate it, flake off what little rust is holding it all together and more leaking. So, I took some Tank Weld and filled around the outer perimeter of the board Been running it like this for a couple months now with no signs of leaks. I can fill the tank all the way up and accurately track fuel mileage now (~ 26 mpg highway with the 3AT, 65 mph ~ 3800 rpms - better mileage than my 94 GT wagon) Side note- replaced the rear fuel filter this morning (started getting some bucking going uphill- classic symptom of fuel filter clog) and found this Looks like sand. Was originally a Florida car. Been dailying it since Spring started.