You could tap the unused holes and fill them with a lock tighted set screws flush with the face of the flange. You really need to be able to pull the mounting screws tight. If the tank material is thick enough that you can tap the existing holes I would do so. If not, use a product called a riv-nut. The riv-nut allows you to put machine threads (rivet nut) in a piece of sheet metal. Use a riv-nut that matches your tank material and is 1/4-20 or 5/16-16. Use cap screws and large washers with the appropriate sealant on the gasket and bolt threads. Using the cap screws means you can torque down nice and tight with an allen wrench. The large washers help spread the pressure more evenly on the flange to prevent leaks.
You have a tough situation cause it is on the side of the tank. Good Luck, Josh Muckley S/V Sea Hawk -- When privacy matters. http://www.secure-my-email.com On Jul 10, 2013 11:16 PM, "Bryan Buttigieg" <bryanb...@gmail.com> wrote: > Has anyone on the list tried to install a fuel level sending unit in a > non-SAE standard 5 hole flange housing? > > My 1971 C&C 30 has a 20 gal Monel Gas tank. The fuel level sending unit > was not working and very poorly installed. The flange holes on the tank are > not the standard SAE 5 hole. Instead there are 10 holes which are drilled > right though. A standard SAE 5 hole gasket will line up with 5 of the > holes, though the screws required are much smaller than for the SAE > standard. (follow the link below to see pictures). My question is, is there > a specific sending unit still on the market that will match this hole > pattern? If not are there any thoughts on how to ensure a leak free > fitting? Should I drill 5 more matching holes in a standard flange? The > collective wisdom and experience of this group would be most appreciated. > > Pictures of the flange holes and a standard gasket lined up with 5 of > the holes can be found at this link: > > https://plus.google.com/photos/118303524002140951082/albums/5899184990232341153?authkey=CPnP5cP1ufSRDA > > > Bryan > > > _______________________________________________ > This List is provided by the C&C Photo Album > http://www.cncphotoalbum.com > CnC-List@cnc-list.com > >
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