Cutting Bed Floor

[Chris]

I want to cut an fuel pump access hole in the floor of my truck. I'm inclined to say using an angle grinder within inches of the gas tank isn't the smartest approach. :erm:

Any experience or suggestions?

[ROKTAXI]

Chris, you may want to cut a larger access hole so you don't get next to vitals with the grinder. I've done this in the past and I've learned that a larger access panel is generally better. Of course that's not always possible but it's just food for thought....

[Brody]

What Marty said on the larger access hole is really a good idea.

To protect the tank and vitals, you can slide some thin plywood or another piece of metal between the tank and the underside of the floor boards. Easier to use a circular saw with a metal blade where you can set the depth. I have done this a couple of times and can say that I didn't like it too much any way I managed to do it. I did manage to do it without sparking things off or cutting holes in stuff I didn't want holes in.

[Andrew]

How much metal do you have to cut and how thick?

Honestly I would use a Dremel. I'm pretty good with those things and I've used it to cut some of the body metal on the Xterra just fine. Now for cutting a ton of stuff it would be a pain but the cutoff discs are small enough to give you good control and not go too deep, variable speed, etc.

[scout man]

How much metal do you have to cut and how thick?

Honestly I would use a Dremel. I'm pretty good with those things and I've used it to cut some of the body metal on the Xterra just fine. Now for cutting a ton of stuff it would be a pain but the cutoff discs are small enough to give you good control and not go too deep, variable speed, etc.

:D I used this approach for a while, on that sort of metal for that size hole it would probably be a couple packs worth of cut-off discs. They wear down so fast on thick-er metal. He is right though, tons of control and no way to really cut too deep, if you have enough patients for it.

[Chris]

I have an access cover for the fuel sending unit but 6" away is the fuel pump. I don't want to have to drop the tank again so I was planning to cut a 12" square giving me plenty of access. The problem lies in the clearance between the floor and the tank itself. Not much room and I don't really want to drop the tank just to cut the hole. It's the bed floor so it's pretty heavy duty with reinforcing.

[Warrlord]

Something like this maybe? No sparks & won't punch a hole in your tank................

http://www.amazon.com/Grip-On-Tools-14430-Pneumatic-Power-Shears/dp/B000IEUN6E

[scout man]

that might do the trick. Your welcome to come by and use my compressor if you go this route.

[Chris]

Yeah, I'm thinking I'll impose on my son-in-laws brother and use the shop nibbler which I'm guessing every body shop must have.

[scout man]

:thunb:

[Brody]

Ahh Yes, the Nibbler1 Best suggestion/decision of the bunch. Forget about those things mainly cause I never use them, but for an ex sheet metal guy to not think about them......

[Brody]

Ahh Yes, the Nibbler! Best suggestion/decision of the bunch. Forget about those things mainly cause I never use them, but for an ex sheet metal guy to not think about them......

[1freaky1]

Chris I have a electric shear like Larry posted up that you can use if you want to,,,, So far out of all the access holes I have cut for this purpose I've used them, the sawzall, and jigsaw. The shears work good as long as you can move them up and down to follow the ridges in the floor.

[Chris]

but for an ex sheet metal guy to not think about them......

My memory's not as good as it used to be Pete.

Thanks Sean, I'll keep that in mind as option #2

[Brody]

My memory's not as good as it used to be Pete.


HAHA...Nor is mine. I don't really have much flooring to stand on when I remind someone else about their failing memory...

[Chris]

Turns out nibblers aren't that common any more but http://www.perryandterryautobody.com/ did it for me. The safety key was blowing air through the area while cutting. Thanks to Pete for buttoning it up for me.

Next time my fuel pump fails it'll be a 10 minute job instead of 6 hour. ;)

[scout man]

Next time my fuel pump fails it'll be a 10 minute job instead of 6 hour.

Dang Chris, you must go through fuel pumps like I do drive shafts!!

[Chris]

Only once Steve but dropping the tank in a motel parking lot isn't my idea of fun, I don't ever want to do that again.

[scout man]

i bet

[sanddawg]

You can also use a large rubber mud flap works very well to cover the tank.
I just remove my truck bed slid it to the back of the truck. Done in 3 hours max.

[Rob]

:pics:

[1freaky1]

:pics:
Xs 2

[Chris]

Geez, it's just a hole in the floor. I'll take pics tomorrow. ;)

[1freaky1]

Chris you know how we are about pics! We live for them even of the smallest things LMAO!

[Rob]

Geez, it's just a hole in the floor. I'll take pics tomorrow.

:lmao:
You'd probably say that about not taking pics at the Grand Canyon: "It's just a hole in the ground!" ;)

I should watch myself. I helped a co-worker change the oil in his '99 Pathfinder today and didn't take any pics. Then I took the stock rear lower links off the FJC and put the Toytec beefed-up links back on for Moab. Sprayed the bushings liberally with white lith and covered all the rust with black rust reformer. (Now I'm not getting an annoying clanks and rattles from those LCAs. I was worried that it was something serious going on under the rig, like in the transmission, considering it was clanking badly whenever I shifted. It's amazing how bad LCAs can sound.) And put the BFG AT's back on, also for Moab. Still no pics.

On the other hand, this would be considered routine maintenance stuff. You actually cut a hole in your bed. That merits photos. :)

[Chris]

Okay, here's the pics: After removing the offending section, after Pete added a tab and tapped a couple mounting screws and third with some caulk to keep the elements out.

[Rob]

That's what I'm talkin' about. Looks good, Chris. That unit looks like the one on the 40. What do you think it would take to get those screws out?

[Chris]

Mine come right out Rob, you have something similar I presume?

[Rob]

Looks exactly like yours. Looks like they're rusted solid. I'll find out one of these days.

[Chris]

Start soaking them Rob, you know the drill ;)

[scout man]

yup, just wire an extra windshield washer nozzle down there and fill it with PB blaster... hit the button everytime you get in or out :D

[Rob]

just wire an extra windshield washer nozzle down there and fill it with PB blaster... hit the button everytime you get in or out
:lmao:

If only I knew anything about wiring. I did hose them down when I was replacing the rusted out cover with an unrusted one.