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Thread: Ascona Fuel Sender Micro-Surgery

  1. #21
    Cunning Linguist Site Supporter My location tekenaar's Avatar
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    ExclamationTank sender/pickup gasket dimensions

    Quote Originally Posted by Aardvaark View Post
    It looks like my '75 Manta's sender will need to be pulled as the gauge isn't all that accurate. Probably the float isn't completely floating.
    Could someone do me a favor if it isn't too much trouble and post the cork gasket dims., OD, ID and bolt circle dia, (5 holes @ 72 deg) for the flange? Bolt hole dia would be nice too.
    It will allow me to make up a couple of gaskets ahead of time. OGTS is out of them at the moment.
    Thanks.




    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

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  3. #22
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Big thanks, Otto!!!
    Last edited by Aardvaark (R.I.P.); 04-30-2008 at 04:14 PM.
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
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  4. #23
    Moderator Site Supporter neuropel's Avatar
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    Quote Originally Posted by alpharm View Post
    Check voltage stabilizer!
    I assume you mean this piece?
    How do I check to see if this is working correctly? I don't want to put 12V on the wrong post.

    Thanks,
    Todd K.
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    Paddle faster...I hear banjo music!
    ________________
    1972 GT 2.4L
    1974 Manta GT/E 2.0 LHU
    1973 Manta Rallye 2.5L
    1967 Kadett L Rallye 1.1L

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  6. #24
    Cunning Linguist Site Supporter My location tekenaar's Avatar
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    ArrowSender bolt hole size . . .

    Quote Originally Posted by Aardvaark View Post
    It looks like my '75 Manta's sender will need to be pulled as the gauge isn't
    all that accurate. Probably the float isn't completely floating.
    Could someone do me a favor if it isn't too much trouble and post the cork gasket dims., OD, ID and bolt circle dia, (5 holes @ 72 deg) for the flange? Bolt hole dia would be nice too.
    It will allow me to make up a couple of gaskets ahead of time. OGTS is out of them at the moment.
    Thanks.
    . . . didn't see that the first time. The bolts are M5x0.9 with 8mm head (wrench), so I'd say the bolt holes are 6mm (~15/64") . . . hey, it's German . . . everything's metric!


    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

  7. #25
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    Voltage Stabilizer

    Todd,

    Do you have any fluctuation in the engine temperature gauge? Does it show "hot" even when the engine has been running only a short time? If not, the voltage stabilizer is probably not the culprit unless your stabilizer is failing due to gradual heating over time.

    I have a few of those stabilizers (new and used) if you need one.

    Dave

  8. #26
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Quote Originally Posted by tekenaar View Post
    . . . didn't see that. . . hey, it's German . . . everything's metric!
    How about the lug nuts and spark plugs?
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

  9. #27
    Moderator Site Supporter neuropel's Avatar
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    Plastic Floats?

    Quote Originally Posted by David McCollam View Post
    I have a few of those stabilizers (new and used) if you need one.

    Dave
    Nah...I still think it's the float, Dave. In looking back through this thread I like the trick Otto found of replacing the cork float with a plastic one. Anyone know which senders have plastic floats that we could scavenge from a junkyard?

    Todd
    Paddle faster...I hear banjo music!
    ________________
    1972 GT 2.4L
    1974 Manta GT/E 2.0 LHU
    1973 Manta Rallye 2.5L
    1967 Kadett L Rallye 1.1L

  10. #28
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Quote Originally Posted by neuropel View Post
    Nah...I still think it's the float, Dave. In looking back through this thread I like the trick Otto found of replacing the cork float with a plastic one. Anyone know which senders have plastic floats that we could scavenge from a junkyard?
    Todd
    I'd like to know too.
    Thanks
    Last edited by tekenaar; 05-02-2008 at 11:10 AM.
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

  11. #29
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Welp, I fixed my float today using a hardware store bottle stopper cork
    close to the size of the original 1975's sender float. $1.30 for the cork.
    Filled up the tank and it works like a charm. Pics below:
    Attached Images Attached Images
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

  12. #30
    5,000 Post Club My location namba209 (R.I.P.)'s Avatar
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    Congrats Mark, on a very frugal fix the rest of use Opelers can use, if needed.
    Ron
    72 GT 3.4L V-6/T-5/ZF posi - almost done - Just need AC installed.
    75 Chevy monza 5.7L/TH350/Auburn 3.08 posi - Next

  13. #31
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Quote Originally Posted by namba209 View Post
    Congrats Mark, on a very frugal fix the rest of use Opelers can use, if needed.
    Glad to share.
    More info on the cork and gasket a recommendation. The stopper cork is 1-7/16" dia on the big end and tappers down to 1-3/16" dia. OAL is 1-7/16" so it's total volume is very close to the stock cork. A small hole must be drilled for the rod, but I didn't record the size.

    For the gasket, the first time I used Otto's dims but after it leaked at the screws, realized they are through tapped and need to be sealed on the threads. So I made two more gaskets, 1/16" thick each (since that's what I had on hand) and didn't put the screw holes in them, instead just screwing the sheet metal screws that have pointed tips through the gaskets at assembly. Seals good so far.
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

  14. #32
    Cunning Linguist Site Supporter My location tekenaar's Avatar
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    Angry1/16" cork gasket . . . N.O.T.!

    Quote Originally Posted by Aardvaark View Post
    Quote Originally Posted by tekenaar View Post
    Geeze . . .

    When I temporarily mounted the fuel sender/pickup back in the tank to move the car, I did it using a gasket made from 1/16" thick cork sheet. This thickness may be fine for a top mounted sender like the GT, but it presented some "weepage" problems on my Ascona/Manta FI tank. Found some 1/8" thick "cork-rubber" sheet (Felpro 3019-85565) at O'Reillys and fabricated my current seal from it. Should work much better than the thinner cork (only) sheet I used before . . . thicker, and composite cork-rubber material!
    . . .
    More info on the cork and gasket a recommendation. . . .

    For the gasket, the first time I used Otto's dims but after it leaked at the screws, realized they are through tapped and need to be sealed on the threads. So I made two more gaskets, 1/16" thick each (since that's what I had on hand) and didn't put the screw holes in them, instead just screwing the sheet metal screws that have pointed tips through the gaskets at assembly. Seals good so far.
    A little surprised that you'd use 1/16" cork gasket after I'd already said that it had "weepage" problems for this particular use - it's too thin for this application! . . . even gave a part # for the correct gasket material! :banghead:


    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

  15. #33
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Quote Originally Posted by tekenaar View Post
    A little surprised that you'd use 1/16" cork gasket after I'd already said that it had "weepage" problems for this particular use - it's too thin for this application! . . . even gave a part # for the correct gasket material! :banghead:
    Otto, you are apparently unaware of my frugality (what a cheap bast--d I can be). I have a lot of 1/16" Felpro gasoline compatible gasket material on hand and no 1/8". Two gaskets stacked work fine as long as the holes for the five screws are left for the screws to cut and seal.
    Last edited by Aardvaark (R.I.P.); 05-08-2008 at 07:56 PM.
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

  16. #34
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Quote Originally Posted by neuropel View Post
    Nah...I still think it's the float, Dave. In looking back through this thread I like the trick Otto found of replacing the cork float with a plastic one. Anyone know which senders have plastic floats that we could scavenge from a junkyard?
    Todd
    Since one of my retirement pastimes is browsing through car parts catalogs and dreaming, I came across a couple of items that may work for non-cork floats on sender arms. These are for Ford Thunderbirds but look promising for use on earlier than 1975 Mantas/Asconas. Here are links of one of several parts suppliers who sell these for early ford products. Fairly cheap in price.

    Tank pickup suction filter. 3/8" but would probably be made to work on our suction tubes:
    Mac's Antique Auto Parts

    Tank level brass float. May work on pre 1975 senders. I don't know how the float mounts on the arm for carb tanks.
    Mac's Antique Auto Parts
    If anyone lives near any of the early Ford suppliers, it might be possible to take a look and measure them before spending money.
    Last edited by tekenaar; 05-08-2008 at 08:19 PM. Reason: then
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

  17. #35
    Opeler My location dcm013's Avatar
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    Quote Originally Posted by Aardvaark View Post
    Welp, I fixed my float today using a hardware store bottle stopper cork
    close to the size of the original 1975's sender float. $1.30 for the cork.
    Filled up the tank and it works like a charm. Pics below:
    Did you put any kind of sealer on the cork? I need to replace mine too, figured the cork should be painted with something first to be sure it won't get "gas-logged" too quickly. Opinions?

    Don

  18. #36
    wicked wagoneer My location officertyo's Avatar
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    Alot of the newer F.I. car have the plastic floats. I pulled the plastic float i have in my wagon out of a 98 chevy full size pickup.

  19. #37
    Cunning Linguist Site Supporter My location tekenaar's Avatar
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    ExclamationModern "cork" gasket sheets

    Quote Originally Posted by dcm013 View Post
    Did you put any kind of sealer on the cork? I need to replace mine too, figured the cork should be painted with something first to be sure it won't get "gas-logged" too quickly. Opinions?

    Don
    When I went around to look for thicker cork gasket material a week or so ago, one thing I noticed was that "cork" gasket sheets are now made from a composite "rubber/cork" material, for both 1/8" and 1/16" thicknesses . . . appears to be a trend, older cork gasket sheets I have are 1/16" cork only . . . all I could find at the time, though I didn't ask after anything thicker!

    Many stores may still only stock the "cork only" sheets till their warehouses run out of stock and restock with current version. I'd recommend you look for that newer composite "cork" sheet . . . it was about $5 for the 1/16" and $10 for the 1/8" thick "new" stuff . . .


    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

  20. #38
    Cunning Linguist Site Supporter My location tekenaar's Avatar
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    ArrowFloats

    Quote Originally Posted by officertyo View Post
    Alot of the newer F.I. car have the plastic floats. I pulled the plastic float i have in my wagon out of a 98 chevy full size pickup.
    . . . something like this from my earlier post in this thread?



    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

  21. #39
    wicked wagoneer My location officertyo's Avatar
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    yes just like that one. I was skimming the posts in here and saw Aardvaark and neuropel asking what sending units have the plastic floats, Just pointing out 99% of all newer cars use those floats.

  22. #40
    UFOpel Investigator Site Supporter My location Aardvaark (R.I.P.)'s Avatar
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    Quote Originally Posted by dcm013 View Post
    Did you put any kind of sealer on the cork? I need to replace mine too, figured the cork should be painted with something first to be sure it won't get "gas-logged" too quickly. Opinions?

    Don
    No. What sealer would hold up to modern gas? Besides, Cork Oak is nearly impermeable to most all liquids IIRC. It should be fine for quit a while. If not, I'll be under the car again. :banghead:
    -Mark
    '75 Manta
    Having invested my life savings into
    this Opel Manta. I expect big returns.😅
    Link to my album of Opel catalogs
    and magazine articles:
    http://www.opelgt.com/photopost/show...ser/23031/sl/a

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