I'm glad everything is working. I'm not sure if the sending unit was in the car when you drilled it. Seems like it would be tough to get out with the tank in the car. Mild acids are one thing, but I'd caution you about drilling, machining, or introducing any potential ignition sources to a fuel tank. A spark from the bit, drill brushes, static discharge, or short to ground will yield a most undesirable result (ka-boom). I'm glad you resolved your problem but give fuel vapors great respect.
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