LT1-LT4 Modifications 1993-97 Gen II Small Block V8

Trap Door Mod - Cut off wheel without Sparks.

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Old 12-29-2011, 06:38 PM
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Default Trap Door Mod - Cut off wheel without Sparks.

I am thinking of doing the trap door mod to replace my fuel pump using a pneumatic grinder and cut off wheel. But I am a bit nervous of all the sparks that are going sprinkle all over my tank. I know some here do not worry about this and are willing to take that chance that their hoses/tank are 100% sealed. Well that makes me nervous because sometimes during hot days, I can smell gas fumes from the gas cap area, even though the cap is tight. I was under the impression there is a tank vent somewhere under there and I am guessing this is the source of the occasional smell. Can someone tell me there is a fuel tank vent near the gas tank on a 97 LT1 Trans Am?

Also can someone tell me if they know of a cut off wheel that will not generate sparks when cutting metal? I don't want to blowup the car.
Old 12-29-2011, 06:48 PM
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pnuematic shears? pneumatic reciprocating saw at a very low angle?

Siphon the gas out of the tank and wait a day and do it in a well ventilated area?

Have a fire extinguisher ready?

Up the good old life insurence policy?

Old 12-29-2011, 06:51 PM
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Tin snips is all you need. The metal is thin enough to where it won't be a problem.
Old 12-29-2011, 06:52 PM
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drill pilot hole and use tin snips or push car outside and Flame On!
Old 12-29-2011, 07:04 PM
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Guessing you dont want to go through all the trouble. I can never hack my 4th. Gen!! For me, it's doing it right or don't do it at all....not to be a jerk though.
Old 12-29-2011, 07:41 PM
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Originally Posted by Uwilllosetomy93lt1
Guessing you dont want to go through all the trouble. I can never hack my 4th. Gen!! For me, it's doing it right or don't do it at all....not to be a jerk though.
I agree with what you say...I cannot imagine cutting my F-bod. I'd go through the hassel and remove everything before I cut it..I have both intank and external fuel pumps in my car..
Old 12-29-2011, 07:52 PM
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fyi: Youd be better off filling the tank all the way to the top than draining it... its the vapor that is combustible, not the liquid itself...
Old 12-29-2011, 07:55 PM
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You'd have to be a complete klutz and a total moron to accidentally cut into the tank enough to cause a fire. Snips or a wheel - either one works just fine.

IMO, the RIGHT way is to cut the trap door. Once you've done it you'd understand (and likely never do it the old fashioned way).
Old 12-29-2011, 10:33 PM
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I had to do 3 pumps in mine, I did the trap door in mine. Half hour in and out sure beats 9 hours on your back lifting out a rear end and cutting down your exhaust and what not.
Old 12-29-2011, 10:50 PM
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fyi: Youd be better off filling the tank all the way to the top than draining it... its the vapor that is combustible, not the liquid itself...
Absolutely correct. But......if it does have a problem do you want just one big BOOM from the fumes that blows out all the garage windows and deafens the dog, or do you want 15 gallons of gas burning on the floor? Your call.
Old 12-29-2011, 10:58 PM
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Cheap air nibbler from Harbor Freight. Makes nice straight cuts.
Old 12-29-2011, 11:31 PM
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Im doing the trap door this weekend! Sounds like fun.
Old 12-30-2011, 12:01 AM
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It looked like the 4th of july when I changed my pump, don't be a baby and get a 4" cut off wheel on an angle grinder and go to town!
Old 12-30-2011, 12:38 AM
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A nibbler sounds like a good idea. I did not realize they were so cheap. At least they are cheap from China Freight Tools. When I begin cutting, I would still want to put the car outside the garage. And also have the fire extinguisher and marshmallows handy.

I am not worried about cutting the tank or lines, but rather I worry about residual fumes that may be hanging around from a leaking tank gasket or hose. As suggested, I am going to drill a 1/2” hole on one corner. Then through that hole, I will blow out the area with compressed air just to help dissipate any fumes that may be there.

I understand how some may not like cutting their car up, especially if it is in cherry condition. But I really don't want to go through the hassle to take the tank out from the bottom. FTS!!!! Besides, I think having easy access the pump is a nice idea.
Old 12-30-2011, 01:48 AM
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It's a plastic mid 90s Camaro... not a 69 Yenko. I've cut all over my car, but it still looks pretty damn clean I think
Old 12-30-2011, 04:14 AM
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I used a dremal which is not wide auff to hit the tank easy as pie
Old 12-30-2011, 05:34 AM
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You'd have to be a complete klutz and a total moron to accidentally cut into the tank enough to cause a fire. Snips or a wheel - either one works just fine.

IMO, the RIGHT way is to cut the trap door. Once you've done it you'd understand (and likely never do it the old fashioned way).
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Old 12-30-2011, 08:38 AM
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Originally Posted by SS RRR
Tin snips is all you need. The metal is thin enough to where it won't be a problem.
yea thats all u need........i did mine with a phenumatic snip back in the day when my pump was still in the tank.....
Old 12-30-2011, 08:45 AM
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Offset sheet metal snips work very well, that's what I used when I did mine. The hole can easily be patched, I agree it really is the 'right' way to change the pump. 10x easier than the proper method.
Old 12-30-2011, 08:57 AM
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http://www.harborfreight.com/high-sp...saw-91753.html
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