Hi,

If your sending unit looks anything like Grey's photos then it's a goner. On most of them the pipes are toast by the time the wiring has failed.

I had one on a southern car that I bought 6 years ago that still had the cadmium on the pipes and most of the top, but no continuity on the pump wire.

I cleaned up any rust around and under the epoxy knob as best I could and drilled a 1/8" hole right beside the knob on the side toward the smallest pipe. I fed a new wire of the same gauge as the black pump wire through the hole with some shrink tubing around it so that it was a snug fit, and soldered it on the underside to the interior wire.

On the outside, I zip tied the wire to the epoxy knob, and then liberally applied 2 part epoxy around the base of the knob and to both sides of the wire I'd put through the top. JB Weld might be better, as it's thicker and easier to build up.

I then brushed on some tar based undercoating over the whole mess for protection, but also because I knew it would turn gummy if there was a leak and be easy to inspect.

I did this as a temporary repair until I could get a new sender, but have still not got around to replacing it. I've inspected it each year as part of my pre inspection inspection and there's no leakage, but I can't guarantee it's safety in the long term.

Peter
Edit - I recall putting 2 layers of shrink wrap over the wire and then measuring for the hole.