I completed my fuel pump trap door mod today on my 1997 Chevrolet Camaro SS T-Top and decided I would do a write-up to answer any questions anyone may have on measurements or how to do this! So here we go!
- 12" x 24" 22 Gauge Stainless Steel Sheet Metal
- #8 x 1/2" Self-Tapping Metal to Metal Screws
- Permatex Orange RTV Silicone
- Cutoff Wheel
- Eye Protection
- Measuring Utensil
- Marking Utensil
- Straight Edge
- Drill w/ Drill Bit & Phillips Bit
- Phillips Screwdriver
- First, remove all interior plastic from inside the trunk hatch.
- Lay back seat down, then fold carpeting over so its out of the way.
- Measure out your sides for the hole using the dimensions in the picture below:
- Make 2 marks on each side, then use your straight edge and marking utensil to draw a straight line.
- Once hole is marked, use your cutoff wheel and begin cutting along the lines. BE VERY CAREFUL! USE ONLY ENOUGH OF THE WHEEL TO CUT THE METAL BUT DO NOT CUT TOO DEEP OR YOU MAY CUT WIRES AND/OR FUEL LINES! Also when starting your sut, try and avoid creating excess sparks. Remember you are just above the fuel tank and also fumes may have built up above the tank.
- Once the hole is cut, remove and discard the metal piece left over. The fuel lines and pump are now accessible. The lines are not "easy" to reach, be its DEFINATELY easier than dropping the tank IMO.
- You re now ready to swap out the pump. Follow the correct procedures for changing it out.
- Once complete and new pump is installed it is time to make the cover.
- Take your sheet metal and measure and mark the following dimensions the same way you did for the hole. I made the sides slightly larger to account for the silicone and the screws.
- Once your cover is marked off, cut along the lines with your cutting wheel.
- After you have the cover cut out, take your drill and a bit that is slightly larger than the screws, and drill holes in the COVER ONLY. Distribute them evenly and close to the edge to ensure you get a good seal and have room for the silicone and you dont set a screw inside the hole where it will be useless.
- When all of the holes are drilled BEFORE ADDING THE SILICONE, set the cover over the hole and using your drill with the phillips bit, thread all of your screws, DO NOT TORQUE THEM DOWN. You do this before the silicone to ensure you dont create a mess while trying to apply pressure to set the screws.
- Once all screws are threaded remove the screws and cover and place a bead of silicone INSIDE the screw holes around the edge of the trap door hole.
- When the silicone is set CAREFULLY place the cover over the hole without sliding it around to avoid losing your seal with the silicone.
- Thread all your screws again with your screwdriver but DO NOT TORQUE THEM YET! Once they are ALL threaded, tighten them down switching sides after each is tight to ensure even distribution of pressure to get a good seal.
- When all screws are tightened down you are done! Re-install the carpeting and interior plastic, and enjoy!
12" x 24" 22 Gauge Stainless Steel Sheet Metal - $8.47 at Lowes
#8 x 1/2" Metal to Metal Screws - $5.45 at Lowes
Permatex Orange Silicone - $5.95 at Checker Auto (Oreilly's) TOTAL PRICE: $19.87