How to Cut a Fuselage
Cutting down or otherwise custom building a fuel tank for your recreational vehicle is probably easier than you think. As fuel tanks are made from metal, cutting them often creates sparks, which many naturally fear due to the volatile nature of gasoline. But if properly drained and vented, cutting your fuel tank is just as easy as cutting any other light-gauge metal. When reassembling your fuel tank be certain the welds are solid to prevent having to remove and drain it again in order to repair it.
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Instructions
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1
Empty the fuel tank either through the drain plug or by running it empty.
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2
Remove the gas tank from the vehicle. This will most likely be mounted to the chassis. Remove the hose clamps connecting the filler tube, as well as the fuel sending and return lines and breather tubes.
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3
Fill and rinse the removed and empty tank with water, and rinse several times to ensure no gasoline is left inside the tank.
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4
Draw on the lines you wish to cut using a pencil or some chalk.
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5
Drill a hole along the line you drew in Step 4, large enough to insert the blade from your reciprocating saw.
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6
Insert the blade of your reciprocating saw into the pilot hole drilled in Step 5 and cut along the drawn line while a friend braces the tank in place. Grip the saw firmly with both hands and cut slowly along the line to prevent damage to the blade or saw. Once cut, allow for any residual water to evaporate before welding or sealing the tank.
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Tips & Warnings
Never use silicone sealant when repairing fuel tanks, as it is dissolved in fuel and can cause serious clogs.
