Hi,
I reused my old sender unit when I replaced the tank and had the same problem. I put in a gallon of fuel and the gauge didn't pick itself up at all. I thought I'd screwed up.
It was enough for a few miles though so I went down the road and put in 5 gallons of Tesco's finest unleaded and all was well. My sender unit doesn't register 1 gallon on its own but apart from that it's fine. I reckon it gives me a little insurance from running out.
Cheers,
Adam
TR7 V8 DHC Jaguar Solent Blue. 9.35cr Range Rover V8, Holley 390cfm, JWR Dual Port, 214 Cam, Lumention, Tubular Manifolds, Single Pipe Exh, 3.08 Rear, 200lb Spax & Solid Bushes, Anti- Dive, Granada Vented Discs & Calipers, Braided Hoses, Green Stuff, 4 Speed Rear Cylinders, Uprated Master Cylinder & Servo, AT 5 Spokes and Cruise Lights. No Door Stickers. Mine since July 1986, V8 from 1991