Install easy access door for fuel pump

I posted this over at the wagon site. Just in case someone didn't see it, here goes:

Having owned these style wagons and Caprices for 17 years, like alot of us, I have had to drop the gas tanks to replace the fuel pump. Never fails, the tank is usually closer to full than empty and they usually don't fail in your driveway. They will leave you stranded. Joel, is correct, they are dependable and last a long time; but they fail, it's just a matter of time. They two that I replaced one lasted 164K and the other 215K. One stranded me 150 miles from home late at night.

With the rash of fuel pump failures that we have seen, Krzdimond(Robert), Roo and just in the last couple of days COL, I knew the writing was on the wall with my RMW with 157K. If I were Roo's age (and I wish I was), or even Robert's, I wouldn't mind changing the pump. But I'm not and the days of me changing another fuel pump are over, the COL will back me on that I'm sure.

I know Impala guys have cut trap doors to access the fuel pump; but I haven't seen anyone do it to a wagon. I had the time. I also had an extra sending unit, as the tubing from the sending unit has various offset bends. I got out the extra sending unit and got an idea where to cut. VERY IMPORTANT: DROP THE FUEL TANK DOWN AN INCH, FOR SAFETY. I used a dremel with a small cutting wheel. Obviously, you need to pull out the 3rd seat and peel back the rug. I laid the sending where I thought it would go. I then cut a 1" x 1" hole to see where I was.



Bingo, I hit it perfectly, although it is obvious, by the raised area that the sending unit should be there. I then lined up the sending unit on top of the floor to get an idea on the path that it follows. I marked the path on the floor and started cutting.


I took the piece that I cut out and traced it to make a copy. I then added a 1/2 inch all the way around and made a cardboard pattern. I brought the pattern along with the piece of metal that was cut out. I had then cut out the pattern with the same thickness sheet metal and replicate the bends.





I Fluid Filmed (undercoating) the sending unit.



I then put wiring jackets and tie wrapped the tubing to keep it secure.



I drilled the cover for screws. There is one section that is too close to the tank, that you cannot use screws.



I used a small bead of silicon caulking, as it was a good fit.



I screwed the cover on, and there's the finished product.



I figured I turned a 4 to 5 hour job into a 45 minute job (just have to remember to carry an extra fuel pump).

I have the pattern if anyone wants a copy. All and all, not a bad job; with my luck the fuel pump will never have a problem. With the new access door, everything can be done without getting underneath the wagon.


Tom

I love a good Tech Thread! Very nice!

1984twodoor wrote:

I love a good Tech Thread! Very nice!

thanks!

Damn Tom, that came out great.

Wow! Wicked good idea!

My wife is in the market for a wagon, so I will keep you in mind when/if we get one.

Excellent post, Tom!

Next to taking off the rear shocks, dropping the tank and replacing the fuel pump is the worst job. No more for me. Today, I am going down to the sheet metal shop to have them make me another cover for the Caprice Wagon. Then sometime, I will figure out the Fleetwood.

Tom

Nice work Tom. You should get a bunch made and sell these things with a cutting template, I'm sure some wagon owners would buy these.

95brmw wrote:

Nice work Tom. You should get a bunch made and sell these things with a cutting template, I'm sure some wagon owners would buy these.

That's an idea. I'll put you down for two.

Tom

That's a good idea Tom! I don't really mind dropping the tank. Although, everytime I've had a pump fail, it was at home.

Maybe I should do the pump in my wagon BEFORE I take off to Florida.

GasTT wrote:

Maybe I should do the pump in my wagon BEFORE I take off to Florida.

Not necessarily a good idea. My last pump lasted four miles.

Jim would be proud of you...cutting up bodies like that..

So...you think you'll have enough room to disconnect the lines & bring everything up thru the hole?
(Including that funny angle you always have to rotate to get the float out?)
Or you would still do the lines from underneath?

I KNOW your still gonna need bandaids...

looks like the tank is close enough to the floor to pull up on the sender and still angle it out. For me, THAT is the worst part of the whole job lol.

sdstick wrote:

Jim would be proud of you...cutting up bodies like that..

So...you think you'll have enough room to disconnect the lines & bring everything up thru the hole?
(Including that funny angle you always have to rotate to get the float out?)
Or you would still do the lines from underneath?

I KNOW your still gonna need bandaids...

The lines will easily disconnect, there should be plenty of room to pull the pump out and rotate. You may have to get a little slack on the wire. The idea is to not do anything from underneath. The only thing I see, is if the wire is pinched, you may have to drop the tank an inch; but that is only 2 bolts.

GasTT wrote:

Maybe I should do the pump in my wagon BEFORE I take off to Florida.

Roll the dice.

Tom