69 C10 with in-cab tank
I haven't been able to get back to this for a while because ... life. But I have made some progress recently.
Here's a pic of what my plan is. The added stuff is in red, I plan to solder in a 1/4" return line in the depression that is stamped in the replacement sender. Then I plan to put the wiring feed-thru in the space between the return tube and the sender terminal. The little Grainger part was too big. It takes a 1/2 " hole. I decided to try to make one myself. It's in the second pic. It's made of Delrin. It's 3/8-24 thread with 1/2" hex. I drilled the holes for the wires with a #42 drill. It's a snug fit on the wires. The nut is a copy of the one for a compression fitting. It has a small recess above the threads. I can fill that with sealant and tighten down the nut after it cures. That should completely seal up around the wires. I made a sender wrench so I won't have to use a chisel or drift punch to remove/install the sender lock ring. I figure I may be doing it several times before finally getting the pump/wiring done right and I don't think the stock lock ring will stand for much of that.
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A little more progress. I got the return pipe fitted. The replacement sender is made of stainless. That was a bear getting the hole started. I first had the return running parallel to the supply line. I was looking at it and mentally patting myself on the back for doing such a good job of bending when I noticed that it was pointed directly at the gauge sender. Sigh. I adjusted it so it points away from the sender. Probably would have been okay, but it seemed like a less than ideal situation.
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Finally getting back on this project. I finally decided to go with the Force Fuel system instead of the in tank pump. I got the 93502 system that includes the force fuel and the spark box. I got the modified sender installed in the tank. The little sender wrench worked great. I bent up a return line to run parallel to the supply line. The channel in the tank fit both lines and I made a replacement grommet to support them through the hole in the cab floor.
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A little more progress. I believe the fuel system is sorted out. I ran an additional hard line up the frame rail to the front of the truck to serve as the return line. I mounted the Force Fuel in the place of the battery, using a bracket that I made to fit the battery box holes. The battery was moved to the driver side using a reproduction of the aux battery tray that I got from Brothers Trucks
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Great work - you have too much time on your hands!!! What sealant are you using for the wiring nut?
I'm planning to use a product called "Seal-All". It claims to be gasoline resistant.