Fuel tank screw hole repair

[McGillicuddy]

Originally Posted by pelican

screws should be 10-32 fine thread...maching screws - not self tapping !

jb weld,or anything else will prove to be a bad choice...

Thanks for the feedback guys.

Pelican,

I have used "water weld" to effectively seal an aluminum oil pan hole and it has held 5 years or more but that is different. Obviously I'm a little leery that an epoxy would hold up in such a minimal surface area application.

I see your point and concur that threaded 10-32 screws would offer better holding power and be less subject to stripping the holes (which probably happens due to over-tightening). I can still do that on 4 out of 5 holes. But I ask why tanks rarely come threaded, and why virtually all sending units are shipped with stainless deep thread sheet metal screws (sharp but not self-tapping).

The over-size hole is my immediate concern. Repair or adapt are my only options. What's the better way to resolve this? Over-drill the sender or some form of patch?

Leaning toward over-drilling the sender as Normagain opined.

Thanks.