Passing Wires Into Fuel Tank? Bulkhead/Passthrough?
 

I'm currently modifying the stock 2nd gen fuel pump flange for AN bulkhead connectors but aside from the corrosion problems (those things rust like crazy!) it looks like I am going to be very short on space. The stock flange has 3 large wire passthroughs and has placed the level sender in an awkward place. There isn't a lot of room to work and I'm assuming that I will very quickly find out that the -8 feed and -6 return will not fit.

So I am thinking that I need to make another flange. No big deal really, but one thing is stopping me...How can I get the two wires for the fuel level sender safely into the tank? I've spent about 5 hours searching this forum, Google and all the EFI forums for some kind of bulkhead or passthrough, but only came up with one picture (attached to this message) yet no source.

I'm trying to avoid cable glands or messing with sealing wires via silicone unless I really, really have to. The stock passthroughs appear to be molded to the stock flange, so they can't be transferred.

If worse comes to worse I will have to drill and tap the center of a plastic bolt, insert a section of threaded rod and then seal each end with an o-ring. But I have to believe that someone somewhere has made such a part (as I have a picture of one attached). Now all I need is a source.

Thanks!

Aaron, use a bulkhead fitiing, and fill it with epoxy, passes SCCA, and NASA inpection. Carl

I'm kind of looking for something a little more elegant. :)

In all my searching it seems that such a thing doesn't actually exist, so I'll probably end up making my own.

summitracing.com sells them iirc

SummitRacing sells large passthroughs for battery cable, but nothing small. First place I checked. :) I think I have it solved though. I'm going to make a set of passthroughs. I'll post pictures here when I'm done.

yes, I am very interested to see your end product.

I just posted a thread that covers my passthrough solution:

https://www.rx7club.com/forum/showthread.php?t=566383

Fuel Safe sells two different bulk head fittings for in tank fuel pumps . . .

Ah dammit, I just downloaded FuelSafe's catalog and it has exactly what I need. I'll file that away for future reference.

Deutsch makes a hermetically sealed connector designed for motorsports fuel tank usage:

http://www.deutschltd.com/corporate/...r_ftc_spec.asp

.. it's too expensive for my projects, but it's avaliable.

Where the hell were you people 6 months ago? :)

13 years later, since all the old links are dead....

Radium now has a solution for those of us in the US:
Electrical Bulkhead Stud Kit, 6 Pack

And the Aussies have an elegant solution as well:
https://www.efihardware.com/products...head-terminals