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Could it be something grounding out the wire to the sender light? If I remember correctly, John Muir says to test the light itself by grounding the wire to the case. If everything is cool with the light, it will come on when the key is on. This also helps to prove if a sensor has become plugged up and won't function properly (i.e. close the electrical path to ground, which is what it actually does). Maybe you have a bad spot on the wire that is rubbing something that is grounded. Jake Kooser '71 Squareback (the little girl) '66 type 1 roadster (the project) '73 super beetle (Barney, the reason I'm not walkin')