Mike,
Had similar symptoms I guess.... smell of gas, but no sign of leakage. Took sender off and found the cork gasket had dried up and cracked. Couldn't find a gasket (in a hurry) so got some paper gasket material from auto parts store and cut my own. This stuff is not very thick, so I made about three or four (can't remember exactly) of them and stacked them up. Each "layer" was stuck together with peratex aviation form-a-gasket sealant, as well as between the sender and the tank. After two years, everything is still sealed up. The permatex is not very pretty if your using it on exposed parts, but with careful application, you can minimize the effect
- Jim -