Cutting a hole in a metal fuel tank

[Jeff Clark]

I have this diesel Mule that I would like to add a fuel level guage to. It has level indicator on the tank, but I want a gauge on the dash. The hole in the metal tank now isn't quite big enough to get the new sender in. How do I go about cutting it? I was thinking of buying a new tank that hasn't had fuel in it, but they are nearly 300 bucks. Any suggestions?

 

[SRadke]

Hole saw? Can you get the tank off?

 

[n7gxz]

If you're concerned about fire first drain all of the fuel out. Next fill with water to the top and add some liquid soap are you fill. Next cut new hole with a hole saw. Drain water out of tank and let dry. Install new sender and fuel.



Kevin

 

[Jeff Clark]

Yeah, I can remove the tank and use a hole saw, but I was concerned about sparking. I also thought about adding water but wasn't sure if I could do that. I'll give it a try.

 

[SRadke]

Water works well. I've even welded on diesel tanks with fuel in them by filling with CO2.

 

[JLEONARD]

I don't believe sparks will be an issue if using a hole saw.

Jay

 

[Jeff Clark]

I wasn't sure, but I'm pretty fond of my face and would like to keep it where it is.

 

[Rman]

drain it and use a hole saw. You could fill it with water for safety, obviously use care when drying

 

[Mundgyver]

If you are concerned about the water being left over in the tank after draining it after cutting the hole, toss in a couple of pints of alcohol to chase out the remaining residual water with.

 

[MickeyMiller]

Dry Ice

In my distant past, I use to be an Ice Man. Delivered plenty of Dry Ice to shops that were welding on gas tanks. If it were me, I'd break up the Dry Ice, dump it into the tank and go have a cup of coffee. The CO2 should diosplace all the gas/fuel vapors.

 

[GFritsch]

I don't think Diesel will burn without compression. I guess this could be tested by tossing a match into a small amount. Maybe someone here knows different.

 

[Sageair]

Another old trick is to hook a hose up to the tailpipe of a car and fill the fuel tank with exhaust.

 

[JLEONARD]

I know of a few guys who have cut up diesel boat fuel tanks with sawsalls after only draining the tank. Perhaps if your blade was so dull that it turned the metal blue... well, maybe then there would be a chance of danger.

Sharp hole saw, stop halfway thru and let it cool... . that's being pretty conservative IMO.

Good luck.

 

[DIESELMAN]

If you have a hole that is at least 3/8" now, use an electricians slug buster, it is a punch tool. You will need to reach in through the sender/pump opening to insert the cutting side but you can get very, very clean holes up to 8" this way, no sparks and no shavings or chips.