I was originally building my own, but I got a free 10 Gallon plastic cell. So now I am going to use it. Because why not?

The one major problem I have had with my past cars and fuel cells are the ability to measure fuel level.

So has anyone here set up a fuel level sensor and gauge with a plastic fuel cell? If so, what did you use? Did you have the foam inside?

 

The foam blocks can be used with the level sensor. The sensor is inside a tube shaped housing so the foam blocks won't mess with it. The range is typical GM 0 to 90 or 90 to 0. Something like that. I redid mine to work with a stock gauge, more or less. Had to add a resistor inline as well. Did it all in 2003 so don't recall the details. You might better off getting a GM gauge. My results were so-so and can run out of gas unexpectedly because the lower range of the gauge is a slight mismatch, or isn't perfect for the sender. It is in a GLC.

 

The ohm range for the level sender is in the FSM. Just take a resistance measurement of the one you have full/empty and then add resistors in series/parallel for the desired ohms.

 

Your speaking in a language I don't understand here... lol


Care to shed some light on how to actually do that?

 

Fuel level sending unit- full=6 ohms / 1/2=31.5 ohms / empty=80 ohms.
Fuel level gauge- full= 7.4 ohms / 1/2=31.5 ohms / empty= 75.9 ohms.

With these values, it's possible to make the factory fuel gauge work with the fuel cell.

The next task would be to find the ohms of the fuel cell you want to use. If it doesn't have it documented, it's possible to measure it by taking it out of the fuel cell and using a multi-meter to measure ohms of the sending unit wires. Put the multi-meter on the 200 or so ohm setting and place each lead on the two sending unit wires that are not the fuel pump wires. Move the send unit to th top (full) middle and lower (empty) range. Compare these to the factory settings of the Fuel level sending unit. Depending if thr values need to be lower or higher to match the factory values is the hard part. Once you have these, let me know the values and I'll design a circuit that will allow the factory gauge to work.