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WindyJ



Member Since: 18 Oct 2018
Location: France
Posts: 190

Cutting a hole in rear tub floor hole ok?
Any structural reason why a 10cm diameter hole could not be (carefully) cut into the rear floorplan above the fuel tank? I need to change the breather hose as it’s split at the tank end. Normally would need to drop the tank but looks like a right pia so I’m thinking of cutting a hole directly above it so I can access the clip holding it onto the fuel tank. Can’t see why I can’t do that but I’m no structural engineer.... but would turn a few hours job into minutes.
Post #745056 10th Dec 2018 8:50pm
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ickle



Member Since: 22 Jul 2010
Location: South Vendee
Posts: 1726

France 2008 Defender 110 Puma 2.4 CSW Alpine White
I did mine about 6 years ago (110 sw) to fit a dip tube for the Eberspacher cab heater and its not fallen in half yet!


Not a huge clearance under so be careful how you or with what you cut with, I used a Monodex hand cutter then just silicone a flat piece of aluminium over when done.


With a torch, tape measure and a bit of patience, you start with a small hole and can get pretty accurate. IIRC a member on here did a write up on the same procedure on a 90, Danielle Gardel ?


Good luck

Keith
Post #745066 10th Dec 2018 9:26pm
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TJH1985



Member Since: 22 Aug 2016
Location: Midlands
Posts: 238

United Kingdom 
I had the tank out to do mine, it’s a very quick job if you are firm with it from the get go Thumbs Up

Then again when the fuel pump failed, and again to fit the webasto pick up Rolling with laughter

I have changed the design on my tank cradle, so that it bolts on from the underside, rather than sitting on top and haveing to be forced out.


Click image to enlarge
Post #745072 10th Dec 2018 9:53pm
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JimC



Member Since: 22 Jan 2011
Location: NOVA
Posts: 164

United States 2007 Defender 130 300 Tdi HCPU Arles Blue
It’s not that bad to drop your tank a bit. Much better than cutting a permanent hole in your truck.
Post #745084 10th Dec 2018 11:17pm
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DAZ110



Member Since: 06 Dec 2007
Location: East Sussex
Posts: 2000

United Kingdom 2013 Defender 90 Puma 2.2 XS CSW Barolo Black
Post #745088 10th Dec 2018 11:37pm
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ChrisDefender



Member Since: 29 Oct 2015
Location: Midlands
Posts: 445

United Kingdom 
Not a big or too tricky job to drop the tank out. I had it done at a local a few months back and there were no real issues. Better I would have thought than cutting holes! They leak enough as it is!
Post #745147 11th Dec 2018 12:22pm
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c18rch



Member Since: 28 Nov 2012
Location: Sheffield
Posts: 28

United Kingdom 1988 Defender 110 200 Tdi HT Keswick Green
I've made the entire floor removable in mine (110 hard top) using chequer plate to replace the floor and rivnuts. I've had no issues. Makes maintnenace so much easier at the back end, you can stand up into the truck. 1988 110 200TDi Hard Top
Post #745149 11th Dec 2018 12:53pm
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WindyJ



Member Since: 18 Oct 2018
Location: France
Posts: 190

Thx for the suggestions/links people. I think if I had more time and didn’t have to work outside on a wet cold driveway then I’d set about dropping the tank and modifiying the hold points but for this one I’m leaning towards making the whole floorpan removable like c18rch - I can see how that could be very handy in the future!
Post #745155 11th Dec 2018 1:07pm
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Adam17



Member Since: 15 May 2018
Location: Within Bedfordshire
Posts: 1193

England 2004 Defender 110 Td5 XS CSW Java Black
When I thought I had an issue with the fuel level reader/relay/pump (whatever) My mechanic suggested to cut a hole in the boot floor to make reaching it & changing it easier & quicker...

So I would assume it'd be fine! Regards
Adam

Loving The Duchess
The Defender 110 TD5 XS

My Defender story - http://www.defender2.net/forum/topic64005.html
Post #745158 11th Dec 2018 1:18pm
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gazman



Member Since: 17 Aug 2015
Location: Liverpool
Posts: 652

United Kingdom 2003 Defender 90 Td5 HT Alpine White
I've cut a hole in mine. You can buy the right sized plate on Ebay to fit over the hole that is drilled to be riveted or screwed in place 2014 - current ..... 2003 defender td5 90 (my car)
2009 - current .... 2005 zx10r
Post #745316 12th Dec 2018 4:49pm
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Adam17



Member Since: 15 May 2018
Location: Within Bedfordshire
Posts: 1193

England 2004 Defender 110 Td5 XS CSW Java Black
Thanks for the idea. Ill bear that in mind should I need to cut a hole... I think id like to at least try to get thye tank off, and replace any rusty/warn parts, and anti seize all the bolts. Regards
Adam

Loving The Duchess
The Defender 110 TD5 XS

My Defender story - http://www.defender2.net/forum/topic64005.html
Post #745669 14th Dec 2018 12:03pm
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