Hello,
I just got done installing a fuel pump in a 07 Denali. I decided to cut an access hole instead of dropping the full tank. I thought I would share my measurements and photos with you in hopes that it might help someone else who wants to do the same.
Drill out all of the spot welds inside where your cut is going to be. You'll notice that there is some heavier structure towards the back and right sides of the hole. The object of this exercise is to cut just enough of that structure to get your pump out while leaving as much as possible to support your door.
I trimmed out the back structure a little too much. The next time, i will leave a little more of a lip to screw the door down. Save the piece that you cut out- well be using it later.
The floor piece that i cut out
Measurements
I used that piece that i cut out earlier to support the lower left part of the door. I drilled and tapped it with some M6-M10 bolts. Be extra careful when cutting in this area because there is only an inch of clearance to the tank. When i was drilling the bolt holes, i put a piece of metal underneath to keep the drill from going too far and damaging the tank.
Out with the old and in with the new. Be careful not to spill gas everywhere. The sender has one or two quarts of gas in it when you pull it out.
Access back in with black RTV for sealant. I added another piece of metal under the left side for extra support, and simply drilled and tapped in the m6-m16 bolts. The bolts with stars are holding the support for the door, that's why i added the note.
So there you go. I used a swazall to make the cut. Like i said, just take your time and keep your blade depth to a minimum. Be extra careful on the front drivers side of the hole as there is only an inch of clearance under your cut. I hope this helps someone who wants to be able to change their fuel pump easily in the future. I hope to make more of these in the future. I will share my measurements with you
I just got done installing a fuel pump in a 07 Denali. I decided to cut an access hole instead of dropping the full tank. I thought I would share my measurements and photos with you in hopes that it might help someone else who wants to do the same.
Drill out all of the spot welds inside where your cut is going to be. You'll notice that there is some heavier structure towards the back and right sides of the hole. The object of this exercise is to cut just enough of that structure to get your pump out while leaving as much as possible to support your door.
I trimmed out the back structure a little too much. The next time, i will leave a little more of a lip to screw the door down. Save the piece that you cut out- well be using it later.
The floor piece that i cut out
Measurements
I used that piece that i cut out earlier to support the lower left part of the door. I drilled and tapped it with some M6-M10 bolts. Be extra careful when cutting in this area because there is only an inch of clearance to the tank. When i was drilling the bolt holes, i put a piece of metal underneath to keep the drill from going too far and damaging the tank.
Out with the old and in with the new. Be careful not to spill gas everywhere. The sender has one or two quarts of gas in it when you pull it out.
Access back in with black RTV for sealant. I added another piece of metal under the left side for extra support, and simply drilled and tapped in the m6-m16 bolts. The bolts with stars are holding the support for the door, that's why i added the note.
So there you go. I used a swazall to make the cut. Like i said, just take your time and keep your blade depth to a minimum. Be extra careful on the front drivers side of the hole as there is only an inch of clearance under your cut. I hope this helps someone who wants to be able to change their fuel pump easily in the future. I hope to make more of these in the future. I will share my measurements with you
