I agree these tanks aren't perfect, but they are what we can get.  The one I got from Van Café was pretty good and properly packaged with all the holes sealed, but the tabs that hold the sender down were not bent up on the leading edge, making a rotational O-ring compression insertion impossible.  I bent up the tab edges slightly, and with a new sender and O-ring I've had no problems for four years now.  

With all this work I'd also replace the sender. Another $50 is cheap insurance. And you'll have an extra O-ring. ;-) 

Stuart

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Dennis Haynes
Sent: Monday, April 04, 2016 5:45 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: fuel tank seals

The fuel gauge senders can be a real bear to get seated properly. Also, reused senders will sometimes crack. I have had problems with the way some of these tanks were punched out. Unfortunately these aftermarket tanks are garbage. Oh how I wish OEM was still available to for this. 

Dennis
 

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Tyler Hardison
Sent: Monday, April 4, 2016 4:58 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: fuel tank seals

Thanks Dean,

I did a fuel-tank reseal kit while I was replacing the tank. I'm 100% sure that I didn't do the fuel sending unit correctly. :-)

On Mon, Apr 4, 2016 at 1:52 PM, OlRivrRat <OlRivrRat@comcast.net> wrote:

> On 7 Jul , 2012, at 10:52 PM, neil n wrote:
>
> > I doubt that's the case though.
>
>         Actually, That is one of the 1st things I'd suspect ~ If one 
> is not Vanagon FuelTankDrop Savvy
>
> so as to know that the CrossOverPipe is attached to the Underside of 
> the body by a HoseHanger, it is
>
> QuitePossible to Pull one of the CrossOver to Tank Fittings out of the 
> Tank or even Break 1 ~ Those
>
> Fittings can be Seen or Felt by Looking/Reaching in through the 
> WheelWell behind the tire over the
>
> Frame ~ With My long Skinny Arms & Hands I have actually performed a 
> Replacement of a Few C'O's
>
> & Grommets from the WheelWells with out dropping the Tank ~
>
>
>               ORR~ DeanB
>