I'm trying to resurrect a 1987 K75S and need to replace the in-tank wires to the fuel pump. I already have the new wires from EME, but I'm struggling with finding the proper ring terminals. I have plenty of the hardware store insulated terminals but those are not appropriate for this installation. The factory terminals are the Deutsch-style that crimp on both the conductor and insulation, but when searching the usual sources for the same thing all the reviews complain of how thin and cheap they are. I'm not putting something like that in a fuel tank. The only other option I've found is from the industrial sites which only sell in large quantities.

My other idea is to use a standard heavy-duty uninsulated ring terminal along with some heat shrink tubing for extra support, but the PTFE tubing recommended for this requires special equipment to shrink properly without damaging the wire. I've heard different stories about Viton and marine grade heat shrink as far as fuel compatibility, so I'm unsure to say the least.

Long story short, has anyone tackled this issue in the past with success? I'm probably overthinking it (nothing new) but I don't like to take any shortcuts when it comes to the inside of a fuel tank. Thanks as always.

Ebay. You can buy them in fives and tens for pennies. If you already have the correct size insulated terminals, cut the insulation off. I hate those things because they are nearly impossible to crimp correctly without a ratchet-driven factory tool. You don't need any additional support on the terminals because once the pump is back in place, there's no stress on them. Best way to crimp the terminals depends on the manufacture:

 - if they only have a single crimp loop or one pair of crimp ears, trim the wire insulation back so that you can fold it back on itself to make a larger crimp surface
 - if the terminal has two sets of crimp ears, do as above for the inner ears but the outer ears should bite through the insulation. That provides additional support.

I've replaced the terminals on at least four fuel pumps without any problems using single loop/ear crimp terminals.

I've used plain old crimping ring terminals from an auto parts store. The electrons don't care as long as they have a continuity path to follow. No need to insulate.