Fuel pump install question

[SHO--ripper]

Ok so my fuel pump is fried and needs to be replaced. Normally, I'd just bite the bullet and drop the tank to replace it but my clutch and SFB's are also shot and need to be replaced so I'm looking to save as much time as possible. I remember seeing (a while back) a thread that outlined how to cut a section out above the pump and just take it out through the top. Though this seems like a HUGE time saver (as I wouldn't have to siphon out over half a tank of gas, jack up the car, or drop the tank which usually ends up with broken straps and/or strap bolts) but I'm really leery about cutting so close to 9 gallons of gas. I'd like to compile as much info on this procedure as possible before attempting it and also get some feedback as to how safe/easy this is to do. I'm not going to **** myself working on an SHO so if some of you think it's dangerous please let me know. Also, pics on where to cut, what to use to cut, etc. would be great. Thanks.

Edit:This is Chris's brother Joe btw. I always end up forgetting to sign him out and me in. Sorry if I confused anyone.

 

[yamahaSHO]

This question was just asked yesterday or the day before. A search will yield best results as this subject has come up quite a bit.

 

[shopartsnw]

ShoPhoenix has a good write up. You are going to be VERY close to the lines. I would not recommend a saw or cut off wheel.

Personally, I have used a $15 Harbotr Freight air hammer with a notched bit. It cuts the sheet metal like butter and has less of a chance of a spark. It is tough to cut straight, but it is safer.

Good luck

- Mike

 

[RAYJAY]

when i cut out my gas tank hole to replace pump i will use one of these air nibblers

Cut through sheet metal as thick as 16 gauge without distortion. This nibbler is much more precise than shears and it fits in the palm of your hand. Front exhaust protects you and your work.

* Capacity: 16 gauge
* Required pressure: 90 PSI
* Average air consumption: 17.5 CFM @ 90 PSI
* Air inlet: 1/4'' NPT
* Recommended hose size: 3/8''
* Overall length: 8-1/4''
* Shipping weight: 2 lbs.

and at 19.00 bucks its a deal




http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=46061

 

[SHOtime2511]

i just used a simple dremel tool...it took like 6or 7 wheels but
still ALOT faster than droping the tank,like Mike said,ShoPhoenix
has a very good write up in depth with pictures!!