Defender fuel pump access door - Defender Source
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  #1  
Old April 18th, 2016, 08:25 PM
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Defender fuel pump access door

For those who have already done it, post up some pictures, suggestions, etc.



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  #2  
Old April 18th, 2016, 08:35 PM
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I've got a few photos somewhere of those I have seen, best one I've done was just a round aluminum plate from some kind of electrical box cover about 10" across. Rent a giant hole-saw bit, cut, paint cover to match, add arbo around the perimeter, and rivet in place. Easy to drill a half-dozen rivets when the pump fails, doesn't rattle loose, or rust, and looks factory enough to not be obvious with no metalworking skills needed...
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  #3  
Old April 18th, 2016, 08:48 PM
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Not finished yet, but here is the beginning of what will be open access between the supports. I originally was planning on a hatch but I'm starting to think it might make sense to be able to remove a wider section of the floor panel so I can access the fuel lines as well.
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  #4  
Old April 19th, 2016, 08:19 AM
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Good suggestions so far.

I'm also thinking of using a RRC fuel pump trap ddor that I have....


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Old April 19th, 2016, 09:52 AM
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I've cut out a round hole and used D1/D2/RRC access covers. Downside is a slight rise in the floor mat, ie no longer a flat floor.
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  #6  
Old April 19th, 2016, 09:58 AM
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Why bother? Its pretty quick to pull the fuel tank out to do the pump, and its not like you are going to be replacing the pump on a regular basis (unless you are Josh).
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  #7  
Old April 19th, 2016, 10:02 AM
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Quote:
Originally Posted by Jymmiejamz View Post
Why bother? Its pretty quick to pull the fuel tank out to do the pump, and its not like you are going to be replacing the pump on a regular basis (unless you are Josh).
Awesome considering the thread I just started hahahha
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  #8  
Old April 19th, 2016, 10:04 AM
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Quote:
Originally Posted by Jymmiejamz View Post
Why bother?.
For when there are fueling issue on the trail. It allows an easy inspection to troubleshoot, avoiding a 5 day walk back to civilization.
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  #9  
Old April 19th, 2016, 11:56 AM
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Quote:
Originally Posted by Jymmiejamz View Post
Why bother? Its pretty quick to pull the fuel tank out to do the pump, and its not like you are going to be replacing the pump on a regular basis (unless you are Josh).
Because...you know the pump will fail at the worst place on some trail or remote area....it will NEVER quit in my driveway OR when the tank is close to empty! LOL



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  #10  
Old April 19th, 2016, 07:42 PM
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Using that logic I need to great spring access hatches, quick release shock mounts and quick disconnects for anything electrical.
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  #11  
Old April 20th, 2016, 03:27 PM
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Quote:
Originally Posted by leastonce View Post
Using that logic I need to great spring access hatches, quick release shock mounts and quick disconnects for anything electrical.
Brilliant!!

Oh, but most everything electrical already has quick disconnects....


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  #12  
Old April 25th, 2016, 10:43 AM
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Quote:
Originally Posted by Roverlab View Post
I've cut out a round hole and used D1/D2/RRC access covers. Downside is a slight rise in the floor mat, ie no longer a flat floor.
This got me thinking so I used the RRC fuel pump door but I flipped it.
I peeled all the gasket material off, restuck it on the opposite side so the hump goes down.
Kept the floor flatter.


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  #13  
Old April 25th, 2016, 10:56 AM
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Great another place for water to leak in (and out)!
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  #14  
Old April 25th, 2016, 11:25 AM
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Quote:
Originally Posted by Nomar View Post
This got me thinking so I used the RRC fuel pump door but I flipped it.
I peeled all the gasket material off, restuck it on the opposite side so the hump goes down.
Kept the floor flatter.


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What size hole did you need to cut for this? Looks clean
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  #15  
Old April 25th, 2016, 11:39 AM
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Quote:
Originally Posted by Wilboro View Post
What size hole did you need to cut for this? Looks clean
Not exactly sure of the hole size.
I started with the RRC door and just made the hole smaller.
Leaving enough metal to put some small rivnuts in for the door to screw into...
I just jigsawed it---it cut pretty smoothly.
Then I went back and Dremeled the edges to debur them.

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  #16  
Old April 25th, 2016, 11:41 AM
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Just wondering if the door would be an appropriate size for access to my newer tank. This is a lot less
Work than what I was planning.


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Old April 25th, 2016, 11:56 AM
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Quote:
Originally Posted by Wilboro View Post
Just wondering if the door would be an appropriate size for access to my newer tank. This is a lot less
Work than what I was planning.
Hmmm..that's a good question.
My project is suitable for a NAS style 90 with rear fuel tank.
I measured twice, cut once. OK, I measured more than that...but I had to make sure the hole was centered directly over the fuel pump.
I only lost one small section of floor support and you cannot feel it at all.


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  #18  
Old April 25th, 2016, 12:06 PM
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I'll have to track down one of these doors and get the dimensions and see if it's a big enough opening to pull the pump out. I have the exact location I need (mines offset).


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  #19  
Old April 25th, 2016, 12:08 PM
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  #20  
Old April 26th, 2016, 11:01 AM
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Quote:
Originally Posted by Jymmiejamz View Post
Why bother? Its pretty quick to pull the fuel tank out to do the pump, and its not like you are going to be replacing the pump on a regular basis (unless you are Josh).

Jimmy, I failed to mention that I put a brand new pump in the tank....almost a guarantee that I'll need to change it out in a year or so!


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