Aluminum 90 floor with fuel pump access! - Defender Source
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  #1  
Old November 23rd, 2015, 06:35 PM
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Ash Heller
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Aluminum 90 floor with fuel pump access!

Finally got a chance to come up with a floor section for the 90's out there. This is the same construction style as our 110 floor I shared a while back -- all 0.090" aluminum which is substantially stronger than the stock components, and no steel structure to corrode and cause issues down the road.

I've always longed for a fuel access panel on the NAS trucks, similar to what my old RRC's and D1's had, so naturally that was incorporated into this design. The floor needs a tiny bit of tweaking since the port isn't exactly centered over the fuel pump and it drives me a little crazy, but it works as intended so I'm pretty happy with this first run.

Anyways, just thought I'd share. I'm still working on some cool sub-floor storage compartments in these things as well, so I'll continue to post my progress.

-Ash



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  #2  
Old November 23rd, 2015, 06:43 PM
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Nice work!
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  #3  
Old November 23rd, 2015, 07:29 PM
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Way cool!
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  #4  
Old November 23rd, 2015, 08:14 PM
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about time
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  #5  
Old November 23rd, 2015, 08:31 PM
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Centered in floor is nicer than over pump for looks at least especially if it works.
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  #6  
Old November 23rd, 2015, 08:34 PM
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William Skidmore
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Instead of the stiffners why not just roll a bead along the length of the floor? Plans for placing dimples in the crossbraces?
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  #7  
Old November 23rd, 2015, 08:58 PM
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Quote:
Originally Posted by bjf View Post
Centered in floor is nicer than over pump for looks at least especially if it works.
Yeah, I suppose you're right. I'm interested to see how well the access panel blends in once the tub gets bedlined. Do many of you guys run bare floors in the back? Seems like every truck I've encountered runs a matting system of some sort.

Quote:
Originally Posted by airbornrover View Post
Instead of the stiffners why not just roll a bead along the length of the floor? Plans for placing dimples in the crossbraces?
How much stiffness can a bead actually provide? I would be worried that they wouldn't be sufficient. The ribs on this are 0.75" x 0.25" which will provide more than enough strength -- keep in mind that a lot of these trucks are getting loaded down with gear in the cargo area. I'm also not particularly crazy about the look, either.

As for dimples in the lateral ribs: are you concerned about drainage?

Thanks for the input, everyone.

-Ash
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  #8  
Old November 23rd, 2015, 09:28 PM
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Great work, looks like a solid design
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  #9  
Old November 23rd, 2015, 10:06 PM
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Quote:
Originally Posted by bjf View Post
Centered in floor is nicer than over pump for looks at least especially if it works.
Definitely.
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  #10  
Old November 23rd, 2015, 10:57 PM
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That looks fantastic!
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  #11  
Old November 23rd, 2015, 11:27 PM
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Great idea and execution. I'm in the middle of a fuel pump replacement and would literally kill to have had this kind of access! Seriously! Just give me a name ;-) lol

Nice work! So long as it works, I'd leave it centered on the tub floor. Looks better and functions 99% as well as dead centered on pump.
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  #12  
Old November 24th, 2015, 01:16 AM
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I think you should leave the access port where it is, would look a bit goofy being offset and that'd annoy me even more than what you have, only you see it with the cover off.... everyone else see's it the rest of the time.... just my 2c from a nit picky brit
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  #13  
Old November 24th, 2015, 06:46 AM
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Center the access hole over the pump. Function over form. If that offset would bother any rover owner then the spot welds must keep them up at night. Have you fitted and removed a pump yet? I know you have to tip the assembly to get the float out so consider that. 20 years ago I put a rectangular access in my 88" IIA floor when I fitted a custom tank in the rear. Mine used 2 quick release levers and was hinged.
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  #14  
Old November 24th, 2015, 06:49 AM
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Dan Prasada-Rao
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Quote:
Originally Posted by bjf View Post
Centered in floor is nicer than over pump for looks at least especially if it works.

Centered over the pump is what make more sense to me since it's an access panel specifically for the pump. I'd be cussing up a storm if the misalignment of the access panel with the pump caused any difficulty in getting to the pump itself.

Besides, I haven't seen too many people running bare floors in the D90's.

I prefer functionality over pretty in this case.
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  #15  
Old November 24th, 2015, 08:12 AM
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I'm in the functionality camp. Most people have a carpet or mat in the back anyway.

109 Station Wagon models had two covers neither of which were centered. Also, they were square (or rectangular) with rounded corners. In case you wanted to make something with a little throwback to an original LR look.

I grafted a set of them into my 109 2-door tub for the rear tank.
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Present:
1960 SII 109"- "Red Square"
1984 90 Tdi- "Yamelo"
1988 RRC- "Chewbacca"
1987 RRC- "Chewy 2"
2008 RRS SC- "The Supersofa"

Past:
1959 SII 88"- "The Little Green Beastie" last seen in NY
1972 SIII 88"- "GreenHELL" now in NC
1988 90 "Eric the Half a Bee" half a truck, sold for parts
1991 RRC- never got a name- long since recycled
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  #16  
Old November 24th, 2015, 08:19 AM
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If you want technical you are going to have to ask someone else. That if you rolled the sheet metal it would add equal or greater the stiffness that you get from the ribs. There should be vids on YouTube and I know for fact there's a vid from a fabrication show about 5 years ago or so. Showing what a sheet with out the roll beads could hold before flexing and a sheet with rolled beads could hold before flexing.

"How much stiffness can a bead actually provide? I would be worried that they wouldn't be sufficient. The ribs on this are 0.75" x 0.25" which will provide more than enough strength -- keep in mind that a lot of these trucks are getting loaded down with gear in the cargo area. I'm also not particularly crazy about the look, either.

As for dimples in the lateral ribs: are you concerned about drainage? "

Thanks for the input, everyone.

-Ash[/QUOTE]
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  #17  
Old November 24th, 2015, 08:33 AM
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It is all simple math to figure out stiffness and strength.
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  #18  
Old November 24th, 2015, 08:34 AM
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A bead will just be another place for crap to gather in this application. The ribbing and .090 sheet will suffice.
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  #19  
Old November 24th, 2015, 12:11 PM
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Center the hole over the pump assembly. You'll probably have a rubber or rug mat over it anyway.
Yea, "fit & finish" is a definite Defender attribute.

On another note, have you thought about loosening & tightening the big red plastic nut?
Even with the tank removed, you need a strap wrench to do it, so where does that "fit" in here?
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  #20  
Old November 24th, 2015, 12:27 PM
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The proper tool ...or homemade versions of the proper tool will fit easily!


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