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post #1 of 3 Old 11-28-2009 Thread Starter
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Add fuel sender

Want to add a fuel sender to a an aluminum diesel fuel tank. Is it ok just to drill into it with a hole saw when there is diesel fuel in the tank, taking care to vacuum up the cuttings as it is being cut with a shop vac so little falls into the tank? Is this safe or will the battery drill motor spark/s or heat from the friction of the drill be unsafe? jeffrey54@comcast.net

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post #2 of 3 Old 12-06-2009
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Drill slowly with a brace and bit. Use grease on the hole saw to keep most of the filings out of the fuel.
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post #3 of 3 Old 12-06-2009
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Use a nibbler

Try one of these if you can beg/borrow/buy one. It will cut the hole without any cuttings going into the tank.

Sheet Metal Nibblers: Manual Sheet Metal Nibbler Shears, Sheetmetal Nibbler


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