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--any other thoughts anybody has I'd appreciate knowing

Yes it's a very good idea to not peg it, to have a helper & unhook it as it swings rapidly toward(& crosses the F) but with my sending unit having .1 ohms at full tank it's damn near pegged electrically. Take a 5 gal plastic bucket filled w water set next to your tank & run 2 jumper wires to this sending unit & dunk it & w a helper see what the gas gauge reads with the float being raised by the water under operating conditions rather than by hand(I was thinking you might be bearing slightly sideways on the float arm & lessing its contact, kind of grasping for straws now but getting desperate for ideas ). This would give you a good visual for bending it. I still think the resistance wire is the wrong ohms.

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