Thanks for your warnings.

The aluminum is just to keep the vapor level low while the entire sending unit is out of the car. I'm not suggesting anyone use it for more than a temporary cover. It's just much better than a big gaping hole into the fuel tank. I pumped all the other fuel into proper gas cans.


Yes, cutting into and sparks inside closed vapor-filled containers is especially dangerous. Hydrocarbons can soak into the metal and seep out for a very long time. The only right way to do that is to thoroughly clean it and at the final step to keep it filled with water, which becomes difficult when it starts to leak out.

No flames will be involved with this, but this will require a soldering iron at or around 600F. It's essential to let the parts evaporate for days until there is no smell of gasoline or other solvents.


I have a story about all hydrocarbons being flammable... I once bought some tea lights from Kroger that had plastic cups instead of the usual aluminum. The cup itself caught on fire with one of them!