Boyd Tank Installation

[pjmoreland]

Originally Posted by Jason Banks

That's odd. The sending unit on my Boyd's tank doesn't have that square part on top. Only the 2 terminals for wires...

I wondered if they have started using a different sender.

The documentation that came with my tank mentioned both types. I'm not sure why I received this style. It will be interesting to see what type they send me as a replacement.

[andyn]

Kind of off topic but I'm wondering what you did to finish off behind the seat where the old tank was. I'm about to do a tank relocation too

Andy

[pjmoreland]

I didn't do anything back there.

[68ls1]

For what it is worth, this is what I did

[ET702]

Did you buy the panels for the speakers behind the carpet?

[68ls1]

Originally Posted by ET702

Did you buy the panels for the speakers behind the carpet?

Being that I am in Australia we ended up making them, freight quote was $295.00 USD (about $350.00 AUD)

They are like some I have seen on line
https://tinworksfabrication.com/prod...aker-brackets/

[pjmoreland]

EDIT - The leak ended up being from the mounting screws. Adding thread sealant solved the problem.


I received the replacement fuel level sensor from Boyd. They sent me the same kind as the leaky one. I installed it today, and the leak is gone. I couldn't see anything wrong with the old one. There must be a super tiny hole in one of the welds. It has a fully sealed stainless steel body. I tried blowing on the welds with my mouth, but I couldn't hear any air leaking. Very strange.

The sensor appears to be made by a company named KUS.

https://kus-usa.com/product/sss-ssl-sender/

[C101972]

I received the same sender for my tank yesterday and installed it today. Not quite ready to test it yet unfortunately.
Posted via Mobile Device

[pjmoreland]

Originally Posted by C101972

I received the same sender for my tank yesterday and installed it today. Not quite ready to test it yet unfortunately.
Posted via Mobile Device

The sender appears to be well built. Yours will probably be fine.

[C101972]

It looks like a very nicely built sender
Posted via Mobile Device

[indymachinist]

It's nice that they have switched to that type of sender. It should have less issues with fuel slosh moving the gauge around.

https://shop.classicinstruments.com/sn38t

I went with this tube type sender instead of the swing arm sender they provided. I have had my tank a good while though so they may not use that type any more.

[pjmoreland]

My gauge moves around on hills more than the original in-cab setup did. I'm assuming that's because the under-bed tank is longer front-to-back, so hills have a bigger impact on fuel level at the front of the tank where the sensor is located.

[pjmoreland]

The mounting studs I used for attaching the tank to the frame are GM part number 12557811. The local Chevy dealership wants $9.50 a piece!! They sell for about $6 online.

[pjmoreland]

I have a couple sets of these mounting studs available if anyone needs them.

https://67-72chevytrucks.com/vboard/...d.php?t=829891

[pjmoreland]

The first fuel level sensor I installed leaked, and Boyd sent out a replacement. Initially it seemed like the new one wasn't leaking, but today I filled my tank extra high, and the new sensor is leaking as well. I'm interested to see what Boyd has to offer. I'm thinking of asking for the other style of sensor that has the float on an arm. Here's a video of the leak.

https://youtu.be/vA-oJ0Q7T1E

[C101972]

That sucks big time! I removed the float arm type and just installed the same as you have now. Unfortunately I am a long way away from testing mine. Please keep me posted on what happens, sorry again for your extra work and headache. Thanks Chuck
Posted via Mobile Device

[pjmoreland]

Originally Posted by C101972

That sucks big time! I removed the float arm type and just installed the same as you have now. Unfortunately I am a long way away from testing mine. Please keep me posted on what happens, sorry again for your extra work and headache. Thanks Chuck
Posted via Mobile Device

Will do. Fortunately, it doesn't take very long to replace it. Installing a new electrical connector is most of the work. I think I will wait until I've burned the gas this time instead of pumping it out by hand like I did last time.

[C101972]

I’m sure that you have better things to do than keep in practice of replacing your fuel sender.
Posted via Mobile Device

[pjmoreland]

Originally Posted by C101972

I’m sure that you have better things to do than keep in practice of replacing your fuel sender.
Posted via Mobile Device

Indeed!

[Rich72C10]

wow ... that is nuts. Just think if that held a little while and started to leak while sitting in traffic!

[pjmoreland]

Dave Boyd was very quick to respond, and he noticed bubbles coming from one of the screw heads in the video. That's got to be the source of the issue. He said pressure is likely building up inside the tank due to the check valve in the rollover safety vent. I'm going to put sealant on the screw threads to see if that fixes the leak. I'll bet it will. Here's a zoomed in video that shows the bubbles coming from the screw.

https://youtu.be/jBXYp2iC1D8

[Rich72C10]

I don't know about feeling good about that. Is that something you had to put together or it came to you screwed down and should have been sealed from them? Might be a stupid question as perhaps that was explained before...

[pjmoreland]

Originally Posted by Rich72C10

I don't know about feeling good about that. Is that something you had to put together or it came to you screwed down and should have been sealed from them? Might be a stupid question as perhaps that was explained before...

The first one came pre-assembled, although I installed the current one. Dave Boyd said no sealant should be required, but I'm going to give it a try. I did tighten the screws firmly, but I didn't go crazy on them because I didn't want to distort the gasket too much.

[pjmoreland]

I sealed the level sensor screws with Loctite 1158514 last night. I accessed the screws through the wheel well. Probably would have been faster and easier to drop the tank. I drove back to the gas station this morning and overfilled the tank to test it. The sender is not leaking now, so the screws were the problem this whole time.

I do, however, have a small amount of fuel leaking from the vent tube, so I will need to reroute that up into the bed stake pocket to get it higher.

[pjmoreland]

It appears that the fuel pump screws are leaking a small amount as well. I will have to drop the tank to seal them.