Some previous owner of my car hacked a nice hole in the gas tank hump to replace the fuel pump (or something of the sort, the lines don't seem to be cut). Anyway, I am in need of ideas as to how to fix it now.

I am concerned about welding it with the gas tank right there. I don't really want to drop the gas tank, but that might make the most sense and just fix it right with some hammer and dolly to get the pieces in the right shape again. Another option would be to pop rivet a piece over it, but then I have to drill that close to my gas tank.

Pictures are attached.

 

Fix it correctly, it'll look better and be safer. Yank the tank and weld it up. If you put a door in it, make sure it's gasketed. The PO of my car did the same, so I needed to repair mine as well.

 

https://www.thirdgen.org/forums/body...mp+access+door

 

I don't understand what the big deal is with having the access panel. It's not like it's visible.

 

It would bother me. Having a large, hole cut somewhere in the car would **** me off to no end.

It's a ghetto fix, and some people like to do things right.

 

I already fixed it in one of my cars by welding a plate over it.

I'll probably just drop the tank down enough to get room to weld and do it right, I have to pull the exhaust anyway which is the biggest pain of the whole thing.

Amen to doing it right, 99% of the access holes are just hacks, this one was just left exposed and my other had some panel from a water heater siliconed down.

 

I will not cut a hole in my car like that, but if I got a car that already had the hole cut I would clean it up and leave it in case the fuel pump goes out agin. Sine the PO left the stock sheet metal in place I would use as much for it as I could to weld it back together if that is the route you want to take.

 

I would cut it out and cut a square piece of metal and make it removable like "haps" did.

+1 on NOT using this method to change the fuel pump.

 

Safety. Do you really want the gas tank to essentially be in the interior of the car? Imagine the possibilities in the event of a rollover. There's also the opportunity for exhaust fumes to enter the car.

 

To remove the gas tank properly without bending things you must remove the rear-end.

Using the hole to change the pump means you'll have to cut the fuel lines and reconnect with rubber hose and clamps.Not A good idea, IMO.

 

You don't need to remove the rear end. I've done it several times and have never removed the rear end completely.

 

OK you do it your way. I've seen it done both ways. Dyno Don did mine after the first place I took it to left small dents in the subframe. Don always removes the rear-end and has done dozens of them. things.removing it. He maybe the finest third gen mechanic in California. He knows these cars inside and out.

 

You guys are playing word semantics. The rear doesn't need to be "removed", but it does need to be dropped. You will not get the tank out without dropping the rear out of the way and I believe we all know that.

 

AmorgetRS, I must say I am suprised by the mess they left you with. I thought the hole I got from the previous owner was bad but yours looks a little worse to me. Mine has wrinkled sheetmetal but not in the bend by the seat back.

Haps, That is a very nice and neat patch panel you made and fit in. Nice job. I had a different plan for mine but may just do one similar to yours if my plan does not work as I want.

 

Thanks!

 

The rear does not have to be removed but as said it must be dropped. Granted not everyone has access to a lift but this is right after I got my tank out and the tank never even touched the rear on the way out or back in.



The only thing good about the OPs situation is all the original metal is still there. It just needs to be welded back up.

 

AmorgetRS, are you going to replace the whole fuel line sending unit assembly?

With a very neat panel like Haps did my main concern is that most people are using fuel line when they cut the steel lines. I do not trust that at all with the fuel injection pressures of TPI or the V6 MPFI. The only good fixes I have read have been to put
-AN fittings on or to use a compression fitting.

 

Yeah that cut in the body is a hack but when done right I dont see a problem doing a fuel pump this way. The panel would have to be cut out right and made into a access "door" if you will that is gasketed and bolted down or latched in some manner to seal off the interior.


You could try to find a donor car and carefully cut out the sheet metal and replace that entire section of your car, welding it back into place completely. Would be clean after it was done and welds ground smooth and painted over.

 

That is the bizarre part... as far as I can tell they didn't cut the lines. I don't know if the lines were replaced already or the person cut it open and changed their mind because they didn't want to cut the fuel lines.

 

You are most likely right. They were probably familar with many other vehicles that have a way to disconnect everything right there at the top of the tank. When they seen that set-up they were suprised and stopped. (Oh No What do I do now)
My Suburban and my truck both disconnected at the top of the tank. I was not familiar with the F body set-up till I had to work on mine and still only stumbled on the hole cut in mine and then learned about the fuel unit design. I do need to fix my lines.