The in-tank fuel pump in my 97 z28 needs to be replaced. I can either remove the exhaust & rear end to drop the tank to access the pump or cheat & cut out a section of the floor above the tank. It looks like the hole should be 12x8 in or so right near the center of the trunk. Lots of folks cut, but I'm worried it could make the car even more bendy. Any advice?
If you drill intoc the trunk, wrap duct tape around the drill bit about 1/4" from the sharp end.
Ever have a burr grab the drill bit and pull it in through the metal you're cutting? You don't need to do that to a gas tank. Drill a hole, then get a very bright light.
I did it on my Chevy pickup, the tank is behind the driver right where all the road salt, sand and water hangs out with no hope of ery seeing sunlight.
Dan
i have an 84 i am planning to do this with at the suggestion of most of the CMC racers on the forum boards. they dont seem to think it makes any noticable difference in stiffness of the chassis but they all rave at the servicabilty advantages. i plan to take the tank out to cut the hole though so i guess the servicability benefits will be for the second pump replacement!
Thanks for the replies. I'll cut, carefully.
get a bmw, they cut the hole for you. 
BTDT, it's not that bad of a job.
Leave youself plenty of room to get in there and install the EFI fuel hose.
Shawn
2002maniac wrote: get a bmw, they cut the hole for you.
Volvo, too.
I'm sure it would have cost GM $0.11 per car, so the beancounters nixed it.
Its pretty common on the F-bodies:
http://www.gonicd.com/intankinstall/intankpumpinstall.html
Common on Trooper's to cut the floor. Those tanks have a seem that is at mid way up the tank. the seem also has the bolt flange to hold tank up they leak if you drop the tank.
I used a cut off wheel to slice my old floor then mig welded 1 inch wide strip on the under side so i could bolt the cut section back in when done.
Note: my tank didn't leak so no worry about sparks...you might be diffrent.
Seems like many import cars have an access port while domestics don't. Wouldn't that the extra cost of a flap would be quickly offset by the cost savings in reduced warranty claim time for pump replacement?
Someone did a hack job version of the fuel pump access to my 86 Camaro. I have gotten around to making it look better. But I now have easy access to the fuel pump...& it also has a mechanical pump. Not sure what's goin on there. So many projects, so little time.
I'm ready to cut. Where's my pump? I must have checked "Louisiana Fast" on the shipping form. I have no idea where Popeye's came up with that slogan for their commercials.
Gearheadotaku wrote: Seems like many import cars have an access port while domestics don't. Wouldn't that the extra cost of a flap would be quickly offset by the cost savings in reduced warranty claim time for pump replacement?
Correct. All of my RX7s and the Miata have one.
yea... I remember that bear of a job on both my father's Lincoln and my Uncles e150... damn car makers can make a hole
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