Enlargening fuel tank sender hole in floor

[Bus'n it]

I looked at my fuel tank today to see if I had any taps for future diesel/ generator feeds. I was glad to see two taps on top. I would like to cut the steel floor a bit larger to access them and to replace the fuel filler and vent hose since both have some dry cracking. What would you use to cut the steel with? Abrasive wheel on a grinder? (Sparks), carbide tipped saw blade?

[Danjo]

Gas or diesel?

[Danjo]

I think I’d cover the top of the tank with a wet blanket and cut it with a sawzall

[musigenesis]

I found the easiest (and safest, in terms of not cutting through something important) technique was to make a small starter triangular hole by making two cuts with a cutting disk (on my angle grinder) in a V shape, then lightly scoring the third side of the triangle. You can then bend the triangle up and down until it breaks off. I then cut out the rest of my openings in the floor (https://www.skoolie.net/forums/f11/r...tml#post372528) with my electric shears (which can get started in the triangular hole) and more scoring-and-bending-off on the edges.

So the only time I was actually going below the level of the floor with the cutting wheel was to make the initial V cuts, after checking to make sure there was nothing there on the underside. There's a lot of stuff there that could get cut accidentally.