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Thread: Fuel Pump Access - Can I Cut These Out?

  1. #1
    Join Date
    Sep 2020
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    Question Fuel Pump Access - Can I Cut These Out?

    I'm currently creating a fuel pump access hole for my 2006 Defender 110. I have googled heaps regarding this and every image I come across is different to what I have.

    20200914_174624.jpg

    As you can see, I have not one but two steel braces (Sorry I don't know the correct name for them). I have seen examples of one, and they just cut them out.

    Can I just cut both out or will I be doing something horrific to the defenders structural integrity?

    What would you do here? I'm a little concerned.

  2. #2
    Join Date
    Jan 1970
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    I'd be concerned cutting them out. From the comments in the link below several have done it without ill effect.

    Defender Td5 - Fuel Pump Access Hole


    Colin
    '56 Series 1 with homemade welder
    '65 Series IIa Dormobile
    '70 SIIa GS
    '76 SIII 88" (Isuzu C240)
    '81 SIII FFR
    '95 Defender Tanami
    '60 SII 109 ute (gone)
    Motorcycles :-
    Vincent Rapide, Panther M100, Norton BIG4, Electra & Navigator, Matchless G80C

  3. #3
    Join Date
    Jan 1970
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    Quote Originally Posted by gromit View Post
    I'd be concerned cutting them out. From the comments in the link below several have done it without ill effect.

    Defender Td5 - Fuel Pump Access Hole


    Colin

    Surely they can't be all that different under that floor? Or can they?

    On my old '95 D1 Facelift there was a round panel under the mat & let into & flush fit with the floor. Remove two or three screws & the top of the pump was revealed which could be totally removed straight upwards if required.


    Access to fuel fittings & Electrics was a piece of cake.


    Why the hell they didn't co-ordinate that with the section making the floor on yours is anybodie's guess. One shouldn't need to cut strengthening pieces (as that is what it is) to access a main component.

    Mind you, I believe one had to remove the tank for accessing the pump in days of yore, so maybe you have got that setup. Pretty **** poor show though.
    If it was mine I would have no hesitation in fitting an infill piece of 16 or 18g shallow channel facing down to one side of the pump to support the floor before doing that, but as it is not a wide gap, personally I can't see a problem. Just ensure it is fitted to strengthen the floor & not to weaken it. NB Someone on the previous thread suggested using Riv-Nuts. A good idea & them being threaded, would make a more sturdy job of it as well as making it more accessible . Fitting a new shallow U channel should be ok you just need to shift it's new position to the right in your photo, so it is clear of the pump even a bit.


    BEFORE TACKLING THIS JOB ENSURE ANY CHANNEL WILL NOT FOUL ANY COMPONENT GET A MIRROR IN THERE TO HAVE A SHUFTI.


    NB. Don't rest any angles etc on the pump to support the floor. Oh, & don't let the drill slip & stick a hole in the tank.

  4. #4
    Join Date
    Jan 2014
    Location
    Perth Western Australia
    Posts
    1,614
    I really wouldn't be concerned about the small amount you are cutting away.

    The below pic is a Defender 2009 (TDCi, puma) and it looks like one of the braces isnt even there on that model.
    Attached Images Attached Images
    Regards
    Daz


  5. #5
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    Thought I had a better pic off mine in a 2000 defer. Access was already their, I removed it when I put a new floor in.....

    very certain it very much like the pic Dazza posted.

  6. #6
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    Quote Originally Posted by W&KO View Post
    Thought I had a better pic off mine in a 2000 defer. Access was already their, I removed it when I put a new floor in.....

    very certain it very much like the pic Dazza posted.
    May I recommend that the corners are cut with a radius to stop the penetration splitting out wards from the corners?

  7. #7
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    Quote Originally Posted by 4bee View Post
    May I recommend that the corners are cut with a radius to stop the penetration splitting out wards from the corners?
    Agree, I wasnít responsible for the initial hole.....

    The new floor has slight radiusís. Bit hard to tell as itís been coated in Bully Liner.




  8. #8
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    Jun 2008
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    The new Gold Coast, after ocean rises,Queensland
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    yeah, so its been there 14 years before access was needed, cut it out fix it , brace it back up for another 14yrs

    most D1/D2 owners have cut a flap in their rear carpet for access because the bastard pumps have to be removed much too often.

  9. #9
    Join Date
    Jan 1970
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    Quote Originally Posted by W&KO View Post
    Agree, I wasnít responsible for the initial hole.....

    The new floor has slight radiusís. Bit hard to tell as itís been coated in Bully Liner.



    Apologies. Post was meant for Richy_Rich for when he cuts a bigger hole, but I am sure there must a formula for calculating an appropriate Radius. It is surprising how much crap gets in there on top of the pump. I used to clean that from time to time & give it a spray of preservative of some sort. Never had a problem with crappy connections etc.

  10. #10
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    Quote Originally Posted by 4bee View Post
    Apologies. Post was meant for Richy_Rich for when he cuts a bigger hole, but I am sure there must a formula for calculating an appropriate Radius. It is surprising how much crap gets in there on top of the pump. I used to clean that from time to time & give it a spray of preservative of some sort. Never had a problem with crappy connections etc.
    All good.....

    Yes I was quite surprised as well, mine was completely buried.

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