I've had issues with mechanical fuel-level sender on carby models too. On one, the resistor array wore through and gauge read empty fulltime. Another had some sort of damage to mechanism and it wasn't able to float properly on surface. So level was lower than actual always.
Seems some sort of non-mechanical method would be best. Perhaps laser and sensor-array on rod. Then you can also programme in non-linear height-to-volume ratio.
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