Fuel tank bulkhead connectors

The gas tank on my POS Fiero has a bulkhead connector with really tiny pins

I'd like to replace them with soemthing more substantial, so far, I've machined some UHMW plastic to pass through the wires, I don't really like this because it doesn't actually seal. the wires just pass through.

I found this:

http://www.radiumauto.com/Bulkhead-Fuel-Pump-Harness-and-Connectors-P682.aspx

but it's way to tall to fit in the tunnel that the fuel tank is in

Does anyone have part numbers for comparable connector with a right angle top? it only *needs* to have 2 wires, although 3 would be preferred. I've been digging through Mousers parametric search with minimal luck. 

and for the "it's fine put it together" crowd, this is out of a buddies car with a 255 LPH pump, I'm not a fan of toasted wires in a fuel tank, he was lucky it just blew the fuse. 

Thanks-

Eric

Racetronix has a pretty reasonably-priced setup that looks like it might work for you: https://www.racetronix.biz/p/universal-bulkhead-wiring-system-4-way/bcws-001

obsolete said:

Racetronix has a pretty reasonably-priced setup that looks like it might work for you: https://www.racetronix.biz/p/universal-bulkhead-wiring-system-4-way/bcws-001

This appears to be more or less what's already there, but with this, I have the option of providing power through more than one terminal, which drops the current through an individual pin.  it also uses larger 14 ga wire, which increases the current capacity of the terminals. this may be the hot ticket. 

Any other ideas?

I can personally vouch for the quality of the Racetronix kit but I never ended up using it as I ended up finding a simpler solution. Have you considered just running threaded rod or a bolt through the bulkhead and using ring terminals on either side? Use UMHW or teflon washers to seal the tank and isolate the rod/bolt from the bulkhead.

Example: top side and bottom side.

go with your original plan to pass the wires, and seal the area where they go through the bulkhead

They make passthroughs for wires that have a gasket that seals to the wire.  Still not "perfect" because fuel can wick through the wire, but works fine.

infernosg said:

I can personally vouch for the quality of the Racetronix kit but I never ended up using it as I ended up finding a simpler solution. Have you considered just running threaded rod or a bolt through the bulkhead and using ring terminals on either side? Use UMHW or teflon washers to seal the tank and isolate the rod/bolt from the bulkhead.

Example: top side and bottom side.

I did consider that, that was plan B if I didn't like the Racetronix part, I got it in, and am fairly impressed with the quality, and I think it's literally plug and play with my existing sender. 

I got the racetronix part in, it's nice, and I was going to install it later this week, then I found this while ordering relays for my headlights and intercooler pump:
 

https://www.bmotorsports.com/shop/product_info.php/cPath/109_631/products_id/5098

https://www.bmotorsports.com/shop/product_info.php/products_id/5164%7B50%7D248

https://www.bmotorsports.com/shop/product_info.php/cPath/109_631/products_id/5163
 

it has 6 positions, and way bigger terminals, I'm ordering one to see if I can make it work on the sender. 

I'm circling back to this, my fuel pump, or more likely the hose between the pump and the rest of the system is failing, and I have a new tank I need to install. 

I have the Racetronix and Ballenger parts in my hand, I'm confident the ballenger won't fit where I need it to go, and I'm not wild about the terminals in the Racetronix, GT150 terminals are just so tiny.  I'm considering pass through lugs like InfernoSG suggested. they're small enough to fit, with a high current capacity, but I would still prefer a encapsulated connection. 

I found these, but they also appear to be too tall:

https://fuelsafe.com/motorsports/fuel-delivery-systems/fuel-tank-sending-units-gauges/

Any other ideas?

Edit:

This might be a hot ticket if it's fuel resistant. 

https://www.summitracing.com/parts/rhc-21-0006