- Joined
- March 29, 2015
- Messages
- 566
- Reaction score
- 292
- 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.
www.explorerforum.com
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.
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!!!
Initial rough cut:
Edges sanded and deburred, old hanger cleaned:
Carpet cleaned and trimmed:
WeatherTech mat covering hole, to see how obvious it might when I would get finished:
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.:
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...
How to: - Installation of DeatschWorks DW300c Fuel Pump
Getting ready to install the in-tank LPFP DW300c and here is the first part of the job....the conversion of the stock fuel hanger. Definitely one of those "how the sausage is made" videos and likely not for the average modder, but as we all know, sometimes the process can be messy, LOL. Just...
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.
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!!!
Initial rough cut:
Edges sanded and deburred, old hanger cleaned:
Carpet cleaned and trimmed:
WeatherTech mat covering hole, to see how obvious it might when I would get finished:
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.:
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...
