Fuel sender unit petrol leak

[ODProjman]

Hi I have fitted a new rank from Rimmer bros as the old one had the usual pinhole leaks. I also fitted a new sender unit and gasket. I have refitted this several times and the same problem persists which is that when I fill up the sender unit leaks until the fuel level is below the top of the tank. I know I could put less fuel in but often hard to judge.
does anyone recommend a sealant that would work or have any recommendations.
I have checked the tank flange is smooth the sender plate is flat and smooth and the locking ring is tapped all the way round to secure.

[NeilR]

What type of gasket did you fit ?.
I could never get the cork ones to seal, ended up with a rubber one that seems to be ethanol proof as still not seeping
for about 5 years. No idea where it came from, was in one of the various junk boxes, although I suspect it may be SAAB.

[Philip Wardle]

I'm chasing down a persistent fuel smell in the boot, though there's no visible leak. I don't think my new rubber sender gasket is leaking, but while researching found they are available in both nitrile material and viton, with viton being claimed as more tolerant to ethanol fuels. I'm working through other possible causes first because I doubt whether the new gasket has been on long enough to fail already, but next time the gasket's changed I'll use the viton option (can be listed as ARA1502 as well as134574).

[gowerboy]

I had a petrol smell in the boot, turned out to be from the banjo connections to the fuel pump, even though I hadn’t touched the pump in months/years. I fitted new fibre washers, but they didn’t help. New nylon washers from LD Parts solved the problem.

[ODProjman]

Thanks for responses NeilR it was a rubber gasket and guessing nitrile

[NeilR]

I would still be suspicious of that rubber gasket. Take it off & try putting it in a jar of petrol, watch for it swelling up.
It may not be what it is claimed to be (nitrile or viton), but just plain cheapo rubber.

[ODProjman]

Update - apologies to Rimmerbros it was James Paddock who supplied the tank and bits including the sender unit gasket. I have just removed the gasket and it looks like a contortionists bad dream. I have emailed messrs Paddock for comment as the supplied gaskets are clearly not ethanol proof. Will post their response.

[ODProjman]

Just found an eBay listing for Viton sheet. 3mm thick 100mm square £6-15 is what is needed to cut a new sender unit gasket. eBay item number:371731267604

[ODProjman]

Update - apologies to Rimmerbros it was James Paddock who supplied the tank and bits including the sender unit gasket. I have just removed the gasket and it looks like a contortionists bad dream. I have emailed messrs Paddock for comment as the supplied gaskets are clearly not ethanol proof. Will post their response.