LPFP hanger assembly access for DW300c Fuel Pump install | Ford Explorer Forums - Serious Explorations

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LPFP hanger assembly access for DW300c Fuel Pump install

ecoboost_xsport

Mad Scientist
Elite Explorer
Joined
March 29, 2015
Messages
566
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City, State
Orangevale, California
Year, Model & Trim Level
2015 Ford Explorer Sport
So I was really dreading installing the fuel hanger that had installed the DW300c into.


Reason being...I was dreading dropping the fuel tank as we don't have top access from within the vehicle. This would mean taking the driveshaft down, removing the exhaust, removing the filler neck, all kinds of lines, etc. As some of you know, I hang out on the SHO forums alot and posed the question to see what those guys had to do for any pointers before I tackle the task. They all proceeded to tell me they have in-car access from a plastic cover under the rear seat...ugh...I got jealous, LOL.

Anyway, I decided to say "&^%$ it!" and see what can be done from the top. I took the seat out, cut back the carpet and found a small hole with a rubber grommet near where the fuel hanger would be. I used my boroscope to see what was under it and see what was in the way. Well, nothing was! So I made an larger exploratory 2.5" hole that I could easily cap off with a rubber plug I had laying around if I had to abort.

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So after closer inspection, I noticed there was parts of the body that are required for the actual structure, but there looked to be a small window I could make to access the fuel hanger without effecting any of the structural integrity. It would be an odd shape, but it was a flat area that I could easily make a cover plate for when I was done. Sooooo, I decided to just commit...full send baby!!!

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Initial rough cut:
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Edges sanded and deburred, old hanger cleaned:
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Carpet cleaned and trimmed:
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WeatherTech mat covering hole, to see how obvious it might when I would get finished:
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Well, Now I just would have to make a cover plate, which will have integreted gussets for added rigidity and a rubber gasket to seal it up. I'll drill and install some nut-serts and this thing should be super easy to access in the future should I need to!

So latest update: I installed the new fuel hanger from this access hatch. OMG, it was awesome how easy it was to get to. Didn't take a pic of the finished install as it looks exactly like the OEM hanger, LOL. Oh and I used a new hanger o-ring too!

Now, since I am hung over from last night's festivities, all I could muster my strength to do was make a carboard template of the cover I will cut on the shears I have at work tomorrow.:

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I will keep you guys posted as I get this thing closer to being finished. But I'm super-excited about this, as it will facilitate my surge tank project I have been trying to get off the drawing board...
 



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Latest update:

Cut the new plate from 8Ga aluminum plate...pretty thick stuff, won't be putting the indents in as this is way thicker than the sheet metal body.

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Comparison of aluminum plate to template:
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Rough sanded and filed edges:
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Fine sanded and polished edges with finished top/bottom:
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Mocked into vehicle:
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Now just to make the gasket and drill bolt holes and nutserts.
 












UPDATE: All Done!!!

Center punch panel bolt holes:
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Pilot holes drilled:
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Transferred hole locations to gasket:
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Holes punched into gasket (yes to the Crocs!):
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Rivet nutt holes drilled in body:
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Rivet nuts installed:
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Had some DynaMat laying around..helps a bit with sound deadening
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Panel installed:
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Hardware used:
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Seat installed:
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Easy access when needed!!:
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Wow!
Excellent work!
 


















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