Just did my fuel pump, using the hack method. Less the time it took to go out to purchase compression fittings, I did it in 1 hour.

I can't imagine the PITA I saved myself, I probably added a week to the end count of my life.

I used a 4 1/2" grinder with a cutoff wheel to cut out the body and fuel lines. Installed a new pump and compression fittings and put it back into the tank. I used 22 guage sheet metal rivited and sealed with neoprene roof sealant (super adhesive and flexable) to cover the hole. I'll get a pic up after its painted.

Its probably going to take me longer to wrestle off the fuel filter, but i'm probably going to end up putting a universal one in on a rubber line cause its slightly rusted, just slightly

 

Gee... I wonder why.

 

I didn't cut, rivet, or ghetto rig anything on my one hour pump install. I don't see why people think this is such a pain. My tank basically fell out onto my face after I spent a whole 15 minutes dropping the rear, removing the rear section of exhaust and releasing the two hold down straps.

 

Not to say hacking is the way I would go, but for others it'll take longer than 1 hour. My exhaust is fully welded. There's no easy way to drop the back of the exhaust. It's all got to come down, and maybe some cutting of the welds to separate the joints and make extra room if necessary. I'd venture a guess and say others are in similar scenarios.

 

I know mitchell calls for 6 hours flat rate, that was my motivation to cut an access hole and not attempt to waste one of my weekend days. Besides, innovative companies like Honda put them in their cars (access holes).

 

Using a tool that produces sparks when cutting metal to cut a metal fuel line would make me nervous.

 

Very good reasons to call it a hack. Thanks! And people wonder why I call the hackers tools. This is a perfect example of not doing it right. Hell, compression fittings have been known to leak from time to time in houses. Granted, the water pressure is a bit higher in most apps...

Do I need to post up the 'purging a gas tank with acetylene for welding is a no-no' thread again?

As an aside, even with a welded exhaust (unless there is no cat and associated joint) all you need to do is loosen it, pull it off the hangers and slide it aside. It really isn't that bad and it certainly shouldn't take 6 hours with anyone with some form of skill.

 

You can guys can argue this all day. I don't care. I "hack" all my third gens for the fuel pump. It saves a lot of time and strain. As for blowing up the tank with sparks, try throwing a lit match in a can of gas. The flame goes out. It is the fumes that will ignite, not the fuel. Simply, take the gas cap off for awhile before you start cutting the fuel lines. If it makes you feel better, go ahead and take the sending unit loose and blow air through the tank with a shop vac.

 

Yeah, purge the lines before doing this or else you may get a fire.

 

Ripping up the carpet, cutting, drilling, and riveting sounds like it takes more time than lowering the rear, exhaust and tank with a combined 7 bolts. Have you ever tried it the other way? You may be suprised how "not hard" it really is.

 

Yeah, I have done it the other way many times. Hacking the floor board is much easier. Pulling the carpet out of the way takes 2 seconds and the rest is pretty simple. No jack, jack stands, air tools or laying on the shop floor. The biggest plus!!! You don't get dirty!!!!