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Just wondering about using a mock-up to sort things out. Mount the sending unit at the proper angle in a cardboard box made to the exact dimensions as the fuel tank and hook it up...see what happens. leave one side open to move the sending unit up and down.
I have a 69 GTX 440 4-speed, Dana car and have had the gas tank out twice, put in a new tank, two new sending units, Checked all wiring 15 times, checked the gauge, voltage limiter, tried numerous grounds, etc....Sending units work great hooked up out of the car, reinstalled everything...put 8...
Right now I've dropped the tank, put in a brand new sending unit that tested out great out of the car, (it was completely wired and with a good chassis ground, etc.), tested the voltage limiter, tested the gauge itself, tested all the wiring, tested things that didn't even need testing, and...
That is the exact same issue I'm having on my 69 GTX! If you can figure it out I'll K.Y.A. at State and Madison and I'll give you an hour to draw a crowd!