Best tool for cutting access panel

0xDEADBEEF · Oct 31, 2022

There are cars from the factory that have access panels to replace the fuel pump.

I would say it can be done safely with the right tools. Also, I would include fabricating a replacement panel with sealant to keep fumes and gas out and what not as part of safe repair.

Probably by the time you did that you could have lowered the tank.

letitsnow · Oct 31, 2022

Sometimes I remove my fuel pump access panel just because I can.

someotherguy · Nov 1, 2022

rob249 said:
edit; One mans punishment is another mans improvement. Nice job belittling some guy on the internet for no reason, Good job there Dick!

I do hope you'll be OK.

Richard

someotherguy · Nov 1, 2022

0xDEADBEEF said:
There are cars from the factory that have access panels to replace the fuel pump.

I would say it can be done safely with the right tools. Also, I would include fabricating a replacement panel with sealant to keep fumes and gas out and what not as part of safe repair.

Probably by the time you did that you could have lowered the tank.

Pretty much this, 100%

I own a car with one of those access panels. Designed by the engineers that do this for a living, and built as part of the car's original structure, stamped in the floor panel during the making of the body, not cut in later as an afterthought. Right there under the back seat.. sealed with a rubber cover.

And ya know what? Even those really smart guys don't always get it right. There are some reports of those fuel pumps cracking and failing, and leaking gas at the top of the sender, gas pooling up, and in a few rare cases, causing a fire. Looks like a supplier issue on the pump/sender assembly that affected certain years/models.

But yeah, I'm sure a DIY job would be better

Richard

thinger2 · Nov 1, 2022

Okay, I also think it is better to solve the pump failure issue first and I think this is a bad idea because it is inside the cab and not covered by a seat.
I too have japenese cars with tank access under the back seat and german cars with tank acess in the trunk.
And german cars and caddillacs with the battery under the rear seat.
The seat is a VERY temporary fire barrier.
but it is designed to be a barrier.

If you do this, dont even bother with the oscillating tool. It will do it eventually but it will cost you an easy hundred bucks in blades.
Dont use a grinder.
Never ever ever put a death wheel on a grinder and get on your knees to cut anything.
Just think about where them chunks end up if it explodes.
I think the jigsaw is the way to go.
Double back tape a couple of hardwood blocks onto the saw base so the blade throw doesnt hit and bend the blade.
Do not cut square corners!
Radious the corners.
Cracks start in square corners.
This is based on having sat through an entire engineering course entitled
"Crack Propagation"
Radious the corners.
If you intend to nail it in place with sheet metal screws use the shortest grip screws that will do the job.
You dont want a bunch of uneeded screw hanging out to puncture your fuel tank in the event off a crash.
And seal it really well and keep an eye on it.
Fuel vapor leaking into the cab isnt the biggest issue.
Exhaust gas leaking into the back of the cab can be fatal way before you notice it happening.

Caman96 · Nov 1, 2022

You’ll be fine. Lol

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Erik the Awful · Nov 2, 2022

I think your chances of fiery death are being exaggerated. Your real concern is your plans for the truck. Cutting a hole to access the fuel pump raises the jankiness level of your truck considerably. If you don't GAF, then you do you. I do stupid stuff, and cutting a hole is a step too far for me.

Best tool for cutting access panel

0xDEADBEEF

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letitsnow

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someotherguy

Truly Awesome

someotherguy

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thinger2

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Caman96

OEM Baby!

Erik the Awful

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