"Wallered out"

I like that phrase,I'll start using it in Western NY,it will be Huge!! Huge is a Western .NY expression,(like "wicked is to Mass.)

BTW I got that wilbur shoe(another good term,thanks gfs) from Wema,I can already see that there's no way I will be able to do this without a whole lot of screaming.I think your right Blue,I'm going with the redrill new holes route.

When you drill and tap the new holes put some grease in the "flukes" of the tap, most of the shavings will stick to the grease and not fall in the tank. I know the fuel filter will pick them up, however........I'm the king of "whatever can go wrong"....will!! :)

As long as the metal isn't corroded, and you've got the right drill and tap, it's probably the easiest solution. I like Don's idea with the grease. Didn't think of that. But my tanks were empty when I did it, so I could vacuum out the shavings.

Naw, Dave your solution was clear, and in fact that's exactly what I did. I was just trying to come up with a simple way to hold the snazzy Wilbur ring in place.

Just use a pneumatic drill to bore your tap holes, John.

Far better than boom.

Cheers,
GFS

Yep Gillie,that's what I'm going to use,I'll also bring my old egg beater style hand drill along in case I feel unsafe.
I may also put a piece of duct tape over the big hole for the sending unit to keep the bulk of fumes at bay or maybe a wet rag stuffed in the hole as Don V mentioned.
My thanks to all of you for the help with this..