Best tool for cutting access panel

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rob249

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Hello All, Im looking to cut a fuel pump/sender access panel in my 94' GMC Yukon, 2 Door. Ive looked around the forums and youtube quite a bit, just havent found any that show the 2 door yukon, but I think i have about 1.5" of space between the floor and the top of the tank.

I was thinking about using a jigsaw, with a short blade, or possibly cutting a blade even shorter. Im also considering an oscillating tool, but ive never used one. Dont have a good enough compressor for and air nibbler, but that seems like it would also work. Trying to avoid sparks for obvious reasons. Anyone tried either of these?

The hole will then be covered with a plate of steel or aluminum, bolted at the corners and middle, with some sort of sealant(RTV, Silicone, or possibly a quality marine caulk like 3M 4200). Carpet will probably be removed and replaced with roll on bedliner, with a rubber mat on top.

I recently did this to my F-350 with dual tanks, and its by far the best mod I have ever done to a vehicle, and all cars should have access panels from the factory. I cut these with an angle grinder while the bed was off the truck, so i didn't have to worry about sparks.

Anyone cut an access hole with the tank in place? What did you use? Thanks
 

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Caman96

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The Bosch stainless steel blades are shorter but I’d probably still stand-off the bottom of jigsaw with some 3/4” material or cut the size of hole you want in a piece of 3/4” plywood, drill a hole and cut along the cut-out in plywood. Or clip the blade, both will work!:superhack:
 

stutaeng

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Drill some large diameter holes in the corner and do the straight cuts with sheet metal shears. I think they sell metal shears that are electric or can be added to a cordless drill.

What/why are cutting holes in your bed or floorboards for anyways?
 

Caman96

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Drill some large diameter holes in the corner and do the straight cuts with sheet metal shears. I think they sell metal shears that are electric or can be added to a cordless drill.

What/why are cutting holes in your bed or floorboards for anyways?
Fuel pump access panel. For the record, I don’t recommend doing this.
 

rob249

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This is a yukon, no bed to remove. Im cutting a panel to make roadside pump changes simple. Tank has been out twice in the last three years, not doing that anymore, a removable panel is far superior in every way. Good idea with the jigsaw standoff, didnt think of that. As far as shears(im assuming you mean aviation/tin snips?), they make a pretty messy edge.
 

Donald Mitchell

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I have did this with a jigsaw but if I had to do it over,(for safety's sake), I would use a floor jack and lower the tank a few inches for clearance.
 

Hipster

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I can't really condone it this way either, get t-boned, a ruptured tank, and the panel pops loose you or family members get covered in flaming hot gasoline. It doesn't sound superior to me.

You've had the tank out 2 or 3 times already so you're not fighting a crusted up mess so there's really no need to hack it and wack it by cutting a hole in the floor and doing a patch job where there shouldn't be one.
 
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Jeepwalker

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A possibility some might choose could be a thin 4.5" disc on an angle grinder.
 
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