So, fuel pump is officially shot. Yay me! I've decided to take the good-old "cut a hole in the hatch" trick, and figured I'd be ok to use a dremel to cut the initial hole. However, I want to cut a smaller hole than the one that spans across the whole deck, and figured I could make it smaller if I also don't remove the fuel sending unit. So, I decided I would cut the metal fuel lines right after the pump, and replace it with short rubber lines (<4 inches). What would the best way to cut these lines be? A line cutter won't fit, the dremel would probably produce too many sparks, so what else is there?

 

One of these mini tubing cutters works in limited spaces

http://www.harborfreight.com/1-8-eig...ter-92878.html

You can always use a hacksaw blade somehow.

 

Use a plumbers tubing cutter.

 

You do understand that the pump and sending unit have to come out as an assembly, right? I don't know what you mean by saying if you "don't remove the fuel sending unit," because the sender is physically above the pump. You can not remove one without the other.
Cutting these with anything but a tubing cutter will put a lot of metal into al of those lines. How are you going to flush those shavings out?
Cutting those with a tubing cutter could reduce the tube diameter if you force it too much.
By the time you get this figured out, you could have unbolted the shocks, brake line bracket, and exhaust, lowered the axle, disconnected the fuel lines, and pulled the tank out. All while not pulling the rear seats and rear carpet, and not filling your car interior, fuel lines, tank, and engine with metal shavings.

 

I will 101% agree with Lurbie here if the car is at all nice , do it right !

Now if this is some clapped out half rotted out beater daily driver that your just tryin to squeeze the last few miles out of , the folks who suggested the plumber's tubing cutter are to be paid attention to , and loose the idea of using ANY kinds of rubber to rejoin the fuel lines , use compression fittings instead .

So antonov225 , which is it , a nice car that deserves proper repairs , or a crapbox that one more hole really won't make a difference to ?

 

Definitely this one! It's a long-term project for me, so eventually it will be nice. However, I just need the damn thing to run right now, so whatever is easiest.