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  #1  
Old 10-17-2010
Bob Johannesen Bob Johannesen is offline
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Default Repairing Fuel low and fuel contamination sensors.

My sensors on the fuel tank had corroded enough that one of the spade connectors broke off in each sensor. I located them new from a Robertshaw distributor for $156.00 EACH! After my Chief Financial Officer regained her balance and said "We'll put them on the list, but I don't know when.....".

So I figured I couldn't lose by trying to repair them. I removed them and only got one armpit full of fuel! I then took my Dremel tool and did some micro-surgery and exposed the little stub that the spade was attached to:



I gently soldered a wire to the stub, put an extension on the other lead, and sealed it all in silicone with heatshrink around the sides.



Ugly but sealed:



I installed each one within an FS electrical box epoxied around the sensor to the fuel tank so it would be protected from corrosion and damage from armadillos failing the road test!

Have to use some fuel before I can test the fuel low light! And there is no water in the sump!

.Ya'll drive Safely!
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Bob & Judy Johannesen
1991 WLWB "Seldom Blue"
1978 FC "Smell The Roses Now" SOLD...Costa Rica
Argyle, Texas
940-300-5257

FMCA #72567, WL #1986, Vintage Birds # 345,
IBA #11205
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  #2  
Old 10-17-2010
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Christian Christian is offline
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Quote:
Originally Posted by Bob Johannesen View Post
My sensors on the fuel tank had corroded enough that one So I figured I couldn't lose by trying to repair them. I removed them and only got one armpit full of fuel! I then took my Dremel tool and did some micro-surgery and exposed the little stub that the spade was attached to:



I gently soldered a wire to the stub, put an extension on the other lead, and sealed it all in silicone with heatshrink around the sides.



Ugly but sealed:

.Ya'll drive Safely!
I noticed 3 terminals when you started and only two wires emerging from the repair pic 2nd above... was the third a ground or did I miss something... mine also is non functional
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FC35SB 1982
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Old 10-17-2010
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sfedeli sfedeli is offline
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There are three wires- depending on how you want to wire the alarm. They can be "normally on" or "normally off".
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Old 10-17-2010
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Bill Pape Bill Pape is online now
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Good job Bob,
I like the old Simpson Meter,
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Old 10-17-2010
Bob Johannesen Bob Johannesen is offline
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There are three wires- depending on how you want to wire the alarm. They can be "normally on" or "normally off".

That is the TEST terminal - you can complete the circuit with a momentary buttton to light up the light on the dash.....I did think about running another wire for that test function but I talked myself out of it!

I just hope the fix works - I will give the fuel low warning light a chance before refueling the tank. It is about 3" from the bottom so it isn't too low.

Old helicopter pilots do not like FUEL LOW WARNING lights!
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Bob & Judy Johannesen
1991 WLWB "Seldom Blue"
1978 FC "Smell The Roses Now" SOLD...Costa Rica
Argyle, Texas
940-300-5257

FMCA #72567, WL #1986, Vintage Birds # 345,
IBA #11205
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Old 10-17-2010
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Bill Pape Bill Pape is online now
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Bob,

Do you remember the pipe thread size to install a plug??
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Old 10-17-2010
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Christian Christian is offline
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Old helicopter pilots do not like FUEL LOW WARNING lights!
I should say not!
Kind of reminds me of that movie w/the crazy judge who flys just over the 1/2 way mark an tries to make it back.. (and justice for all)

Does this sensor have a float? How does it work?

So the test cct would go through the closed contacts on the sensor testing only the common contact and the bulb cct...
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Old 10-17-2010
Bob Johannesen Bob Johannesen is offline
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Bill,
Of course they were two different sizes. I believe the fuel contamination (water in fuel) on the bottom sump was 1/4 inch pipe and the fuel low light was 3/8 pipe. I re-confirmed that before I turned the last few threads out! I was surprised when I didn't lose very much fuel. I tied a shop rag to my wrist and didn't get too much in the armpits! Had the plug on the allen wrench "at the ready"!

Have fun!



Quote:
Originally Posted by Bill Pape View Post
Bob,

Do you remember the pipe thread size to install a plug??
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Bob & Judy Johannesen
1991 WLWB "Seldom Blue"
1978 FC "Smell The Roses Now" SOLD...Costa Rica
Argyle, Texas
940-300-5257

FMCA #72567, WL #1986, Vintage Birds # 345,
IBA #11205
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  #9  
Old 10-18-2010
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Bill,
Of course they were two different sizes. I believe the fuel contamination (water in fuel) on the bottom sump was 1/4 inch pipe and the fuel low light was 3/8 pipe. I re-confirmed that before I turned the last few threads out! I was surprised when I didn't lose very much fuel. I tied a shop rag to my wrist and didn't get too much in the armpits! Had the plug on the allen wrench "at the ready"!

Have fun!
Thanks Just curious, Good to know standard pipe thread. Usually the easy reapairs always have a hitch.
I'll put this in the notes. I have a bag of plugs.
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