20 minutes ago, grannyknot said:

I didn't even think to check those nuts, glad you found it.  I guess the fuel sending unit was dipped in CLR too many times, removed some coating and is corroding up quickly.      I think the bottom of the hatch isn't sealing up well because the slam panel and all the supporting metal underneath had to be cut out and replaced, I remember not having much to reference to and the KFV panels were too big and had to be cut up into sections.

If there is a gap it is probably right in the centre where it locks.

The gaps are small, and are slightly on either side of the latch. There are probably plenty of creative ways to deal with it.

Dave had some Safari Gold T shirts made up, gotta love this guy.