Fuel tank screw hole repair

[McGillicuddy]

Originally Posted by pelican

there's another way,to attempt repair - provided the tank's in good condition - if the threads pulled,odds are the tank's pretty old ...it appears you've had some problems with your fuel system...

Only problem I've had with my fuel system was a chunk of what looked like silicone in my supply elbow. I presume that was from the previous owners attempt at sealing the sending unit.

Other than these over-sized holes my tank is in good condition.

I tried to re-tap them at 10-32 but they are simply too big. 12-24 will require me to re-drill the flange on the new sender. Don't know if a M5 size will work or not.

I was hoping to generate ideas but you kind of left me hangin' for your "repair" suggestion. Did you have an repair idea?

Bilgerat's helicoil idea is cool but it'll run me $40 for a kit and I'll be waiting 2 weeks to get it off some backorder.

I also thought about epoxying some pan-head screws to the inside of the tank but the thought of snapping the bond should I need to get in there again is another potential miss.

Any repair thoughts? I'm all ears...