Fuel Sender Plug for I/S Tank

[Foozle]

10-02

Folks:

Is there a less expensive alternative to plugging the fuel sender port on an I/S tank besides ordering the entire OEM fuel unit (#37080-MBY-000)?  (Which, incidentally, Partzilla currently lists as unavailable).

I have an uninstalled kit from Big BF (RIP my friend) - but the metal plate that covers the metal plug and O-ring is flat (not recessed).  As a result, I can't get the mounting bolts threaded - and am afraid of damaging the studs (or worse) by trying to force things.  (I assume the plate goes over the circular brass plug and not directly on the rubber O-ring.  Why else would the plug have been included?).

If you look at #18 on the fiche (URL below), you'll see the OEM fuel sender plate is stamped (recessed) to accommodate the rubber O-ring.

https://www.partzilla.com/catalog/honda/motorcycle/2000/gl1500cf-a-valkyrie-interstate/fuel-tank

I'm not using a fuel gauge,  so I don't need a functional sending unit - just something to plug the hole.

Any ideas?  Anyone ever install one of Bill's fuel tank plug kits?

Terry

[MarkT]

I made a flat plate with 4 holes that matched the tank.  I think the tank has 4 studs that protrude, IIRC.  Then simply an O-ring that fits the matching fixture on the tank, and sticks up above that fixture.  I have an O-ring kit from HF that has the right rings in it.  It's never leaked.  I made the same setup for a friend years ago; far as I know he has never had an issue.

Pretty sure I got the O-ring out of this kit.
https://www.harborfreight.com/382-piece-o-ring-assortment-67554.html?_br_psugg_q=o-ring

But I also have this kit.
https://www.harborfreight.com/225-piece-metric-nitrile-o-ring-assortment-67609.html

But they also sell a Viton kit.
https://www.harborfreight.com/180-piece-viton-o-ring-kit-67525.html

[Foozle]

I made a flat plate with 4 holes that matched the tank.  I think the tank has 4 studs that protrude, IIRC.  Then simply an O-ring that fits the matching fixture on the tank, and sticks up above that fixture.  I have an O-ring kit from HF that has the right rings in it.  It's never leaked.  I made the same setup for a friend years ago; far as I know he has never had an issue.

Pretty sure I got the O-ring out of this kit.
https://www.harborfreight.com/382-piece-o-ring-assortment-67554.html?_br_psugg_q=o-ring

But I also have this kit.
https://www.harborfreight.com/225-piece-metric-nitrile-o-ring-assortment-67609.html

But they also sell a Viton kit.
https://www.harborfreight.com/180-piece-viton-o-ring-kit-67525.html

Thanks, Mark.

Yes, the fuel sender mounting configuration is as you remember.

I have the correct O-ring.  I'm just wondering if I can place it directly beneath the flat metal plate - or if I need to insert the included brass piece (?) in between (it fits snugly over the O-ring).  For the latter to happen, I'd need the flat piece to be recessed slightly to allow sufficient access to the bolt threads.

It sounds like you've successfully done this simply securing the O-ring under the flat metal plate.

I may give this a try.

Terry