Cutting hole in floor to replace fuel sender

[Mango]

Y’all
Has anyone cut a hole in the floor to replace the fuel sender and pump
89 burban

 

[xm20k]

Unless dedicated race car/4 wheeler where you may need to get into it a ton just drop the tank with the straps.

 

[YakkoWarner]

I have not done that on mine, but will admit it seems reasonable (and would have made sense for the factory to put an access panel of some sort there). I'd be real nervous about doing it with the tank in place, cutting metal=sparks and sparks+gas_tank=bad_things.

 

[WFarm]

My Blazer has a very convenient access door, courtesy of the PO. Huge time saver.

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[Camar068]

I thought about it for my truck but didn't want added edges n such to rip dog food bags open, on top of being open to the elements and sealing and such. Being a 'Burb, if you've got carpet or something over it, I wouldn't think twice about it and do it.

 

[bucket]

I added one to my '88 Burb, much like @WFarm has on his K5. I had replaced the fuel pump many years ago and I dropped the tank. It's a 40gal tank and it was 3/4 full. Plus the dual exhaust was in the way. So the next time I had to change the fuel pump, I made the access hatch. Which I'm thankful for now, because all these years later, it's time for replacement pump #3.

 

[Mango]

What did you use to cut the floor ???

 

[Ricko1966]

Depands on how capable you are with a Sawzall. I'd drill my corners and cut it with the Sawzall

 

[Turbo4whl]

What did you use to cut the floor ???

When I did this, I used an air hammer with a panel cutting chisel.

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Finished up with a small rotary cutter. Then cut a larger panel from a salvage bed to cover the opening.

 

[gmbellew]

I added one to my '88 Burb, much like @WFarm has on his K5. I had replaced the fuel pump many years ago and I dropped the tank. It's a 40gal tank and it was 3/4 full. Plus the dual exhaust was in the way. So the next time I had to change the fuel pump, I made the access hatch. Which I'm thankful for now, because all these years later, it's time for replacement pump #3.

take some measurements of your hatch, please, from some reference points. I picked up a piece of burb rear floor thinking id make a cut if/when the fuel pump dies again that id have something to use as a cover.

 

[bucket]

When I did this, I used an air hammer with a panel cutting chisel.

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Finished up with a small rotary cutter. Then cut a larger panel from a salvage bed to cover the opening.

That's exactly what I did as well. Well, except for trimming with any other tool. Not to toot my own horn, but I'm pretty handy with an air hammer, lol.

 

[CalSgt]

Unless dedicated race car/4 wheeler where you may need to get into it a ton just drop the tank with the straps.

I’m with @xm20k on this one…. I’ll add rusted out or clapped out shitbox to the racecar or rock crawler statement

 

[aasleson]

These are the measurements I used based on a YouTube video I found. I used a cut off wheel on a grinder. Have to keep the cut real shallow to stay away from the fuel lines

 

[Mango]

@assleson looks like you could of gone a little further back on the cut ?

 

[aasleson]

@assleson looks like you could of gone a little further back on the cut ?

Not by much, there is a floor support there that I didnt want to cut into