Homemade gauge test tool, C-3826

I think what you propose would be "chrome plating a pig." The sender itself, even original factory ones, are pretty cheaply made, and it defies logic that they lasted as long as they do/ did. Of course we have all read about how bad the repop senders are.

But even if you got a really repeatable sender, the tank itself? What do you do about up/ down hills, acceleration braking, etc?

IF the sender was a quality piece, even as an analog resistor, and non - linear at that, it would be an easy matter to build an analog - to digital converter, (several chips available to do just that) and of course for some cars you can already buy aftermarket clusters. My neighbor rebuilt an original Ferd Broncheroid a few years ago, and installed a really cool all - digital dash cluster

Frankly, in the situation I'm in, being that much more accurate is not something I want to spend time on, but I can certainly see where many would be.

But Ma isn't the only culprit in this mess. YEARS ago, I bought S&W gauges for my old FJ-40 Landcruiser, which then had a 340/ 4 speed. I bought the "matching" S&W fuel gauge and sender. The sender, and the tank had the old - style GM (and others) bolt in flange, so the sender dropped right in. I followed the destructions to the letter for calibration, but the damn thing was never really very accurate

The gauge used a "bridge" circuit, which should have been great, but the needle was not damped at all, so just going down the road, with, say, 1/2 tank, the gauge would flop between 1/4 and full. Considering the money I paid, it was almost useless. I almost ALWAYS carried a Jerry can of gas on the rear.