plasma cutter to cut gas filler hole?

[pikemaster]

hello,

i finally found a stepside bed for my 86 silverado. my truck has auxillary fuel tanks but the bed i bought only has a gas filler hole on the passenger side. so my question is, has anyone cut into their fender to make a square gas filler hole. or would it be easier to buy a brand new original from factory for around 400?
any input would be great

[helmdogg]

I would take and cut one from a donor truck about 1 or 2 in.varound the opening and weld it into your bed. Or take a bed side from a donor truck. You can find one for cheaper than 400! I wouldn't use a plasma cutter, I would use a sawzall or die cutter. You can use plasma to cut opening a little smaller than the piece from other truck, so the cut would be hidden! And weld the new piece over the opening. hope this is some help!!!

[gchemist]

I replace the orginal bed on my truck with a GMC single tank bed. I cut out the passenger side door and had it welded into the GMC bed. Worked out great. Who ever welds it needs to measure, measure, measure and measure. If you look carefully at mine you can tell that the level is off slightly. Still looks good though. Look at my web site under pictures Look at these pictures You can clearly see the tank door welded into the bed.

[82 Silverado 4X]

Pneumatic nibbler to cut the hole in your bedside keeps the distortion down and a pneumatic flange tool to recess the area for the new fuel door would make it flush with the bed side.