many questions here, and a long time since I built the tanks... last century...
You might be able to access my build, pictures on
https://drive.google.com/drive/folde...BjnALbl5jqrp3x
Pictures #128 onwards detail the tank building (don't use any sloshing compound, not necessary. It is still holding good after all these years, but only thanks to the scuffing I did). Installed the inverted fuel on both sides.
- the hole for the sender was big enough for the float, just a hole did it
- sender was mounted mid-way up, guarantees a linear motion of the float arm
- I remember hooking up the gage to the sender and did a dry calibration, don't remember about the rod though
- yes, the guide was fabricated, main consideration is for the flop tube not to tangle itself in the flap doors (which I guess you will install?)
- don't forget the o-ring on the brass head
Hope that helps, enjoy the build