I picked up an aftermarket gauge cluster, and getting ready to install the temperature sensor and noticed that it is a much bigger diameter than the original water temperature sending unit. I don't want to drill or re-tap the block! My question is where do I find a temperature sending unit that will fit in the original openning? Is there such a thing or do I have to do some artistic plumbing?

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KMAN,
What you need is the resistance specs of the gauge you have. It will be somthing like 10 to 120 ohm range. It may say it on the package or you may have to look it up on the internet under the manufactureres website. This info is not hard to find. Once you have that info you can go to just about any parts store and find a sending unit that will fit your car and be compatible with your gauge (ohmic range).
I've been selling VDO temp gauges on ebay for years and have had to deal with this issue many times. Artistic plumbing is definately not the way to go.

Good luck
Frank

Another option is to drill and tap the thermostat housing (water outlet neck) and install your sender there. As long as it does not physically interfere with the thermostat seating correctly in the housing, you're fine.

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一期一会
Too many people who were born on third base actually believe they've hit a triple.

File photo showing temp sended installed in thermo cover.
You need to off-set the fitting from center so it does not hit the "tower" on the thermostat.
DD

I do have a spare thermostat housing and thought about doing it there. they do not have an adapter obviously for the after market one. I screwed up and cut the A.M.U. ( after market unit) and ruined the seal on the small copper tube and leaked the fluid that WAS in it. so that was pretty much ruined. Right? rookie move. "If Im burnin Im learnin". better the copper tub then the motor. as per the past topics, thank God, I can adhere the oil unit to the filter assembly, this by having it in hand makes sense.
Thank you for all the input

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Bummer with the capillary tube. That gauge is done. I much prefer electric temp gauges for this reason and the fact that the sender is almost always smaller. The Stewart Warner deluxe series gauges look period correct in our cars. They aren't really what you'd call cheap, but the look and function is good. Here's a good example. http://www.summitracing.com/parts/SWW-82306/

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Joshua

I would suggest taking the old sending unit and matching it up and finding a make shift adapter, that way you dont have to modify anything. How ever I would not suggest to drill or tap the engine block if you can avoid it.