Tank fuel hoses on early 240s...

[345DL]

My 245 has the usual tell-tale buzzing of the main fuel pump going on, which means that the in-tank pump has given up. I have purchased a new aftermarket sender unit and pump, and today I tried to fit it.

However, I came across an obstacle fairly early on - I couldn't get the fuel return hose off the old sender unit. It turns out that the rubber hose is just a cover for the actual nylon fuel line inside, which is heat-sealed to the metal pipe sticking out of the sender.

I have had a good look on this useful site: http://cleanflametrap.com/transferPump.htm

These two pictures show the problem:




However, his description of re-attaching the hose is a bit vague, and assumes you want to re-use the old sender anyway. However, I want to re-attach the hose to the new sender instead of the old unit: the new sender has a more traditional 'bump' at the end for use with a jubilee clip or similar, as can be seen on the unit in the picture below:


Do you think I can just cut off the nylon which is stuck to the old sender, and just clip the rubber hose to the new sender? I don't feel that this is satisfactory really, as the rubber hose has not been designed to directly carry fuel.

Has anyone replaced the sender unit on an early (ish) car who can shed some light on what best to do?