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Check the ground connection on your fuel sender. If it is not grounded well, then that may be your culprit. Made just the surface the sender is in contact with the tank is clear of paint/rust.

As my tank is completely coated inside and out, I didn't want to rely on the ground through the tank straps. So, I have an Aux ground wire between the tank and the body.

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Kev's suggestion about providing an extra ground wire is spot on but if a known good ground doesn't solve the problem, there are at least two Ford gauges with different length arms that will fit the tank mount. The Ford senders both have the same 73-10 ohm range as the Packard sender. Perhaps an incorrect arm length or bend in the one you have now is the problem with the 1/4 tank reading.

If you don't have an original sender here is a photo of one showing what the length and arm bend should look like. 20cm from the float end to the pivot and just a slight -- about a 5 degree -- bend. Your Ford sender should be able to be corrected and made to work by lengthening or shortening the wire and bending as needed.

An electrical crimp style butt connector or maybe two can be removed from the plastic insulation and crimped to correct the wire length. For US AWG wire sizes the yellow is a bit larger than needed but will work and the blue is a snug fit but wire can be worked in.

Now is about time a hole in the trunk floor comes in very handy.

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After studying gas tanks, I believe that the ground usually comes from the fuel line connected to the tank. So adding a ground wire from the frame to the tank will ensure a good ground.
Wes

I tried an extra ground this morning, and it did not help. The gauge worked for a while (with the livable problem of reading 1/4 when empty) and then a few days after I filled the tank up all the way for the first time, it started reading empty, so I'm guessing either the float sunk or the sensor went bad....I remember there was a post of the measurements on where to cut the trunk to get at the sensor, I will consider cutting a hole to make this job easier....

Regarding the metal tire valve stems, anybody know the diameter of the hole in the rim for the stem?

The valve stem holes are 5/8"---15,8 mm. Will find my little diagram of where to cut the hole in the trunk later today and repost if no one else finds it first.

On Howard's Project, he has a picture of a hole cut in the trunk. See this link:
packardinfo.com/xoops/html/modules/newbb ... at&order=ASC&type=&mode=0&start=240
Wes

That trunk hole location on my project page is good for Clipper style bodies probably thru 50 but Mike's 53 will be in a different spot because of his square gas tank and different spare tire.. I do have the dimensions and photos Ross posted and can provide them if Ross doesn't have the time.

Please do, Howard. Thanks.

Here are the photos and dimensions Ross provided for the 51-4 trunk hole location.

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Thanks very much you guys.
I found another thing I need to fix! New gas tank sender is ordered.

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