Suggestions needed: Repairing a cut hole in floor (rear)
 

It's time to replace the decade old carpet in Green Monster and while the carpet is up I'd like to repair the hole in the floor by a previous owner. The hole leads to access the top of the poly gas tank so I'm assuming the hole put there for easy access a fuel level float sensor on the original tank.

Regardless of the reason, I need a little help on the best way to patch the approximate 5" diameter hole hole.

I was thinking of getting a 7"x7" square of corrugated bed material then using adhesive to seal it. The trouble with bed material is it comes in 16"x48" lengths- way more than I need plush shipping is expensive for an over sized item. And I've read on this forum of members who purchased patch panels don't match the existing floor rib pattern.

Is there a better method to correct this? I'm open to suggestions.

See photo of hole in floor below.

http://67-72chevytrucks.com/gallery/..._CST_039_1.JPG

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

you could find somebody parting a bed that can sell you a portion of the floor...or you could buy the smallest bed patch you can find...

https://www.amazon.com/Bed-Floor-Rep...132798&sr=8-18

if you want to keep access - I did see a guy on youtube make a floor access panel. Let me see if I can find a link.

Link added = https://www.youtube.com/watch?v=gFkRO9Wtvdw

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

don't you know anyone with a sheet metal brake? A patch panel could be made in seconds. I did the same on mine to access the in-tank fuel pump. I used seam sealer to make it watertight to the floor, and 4 sheet metal screws to fasten it.

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

I appreciate the suggestions. I'll stop by my local metal machine shop (a car collector too) and see if he can fabricate something for me for less than the price of a 48" x 16" panel and shipping.

BTW- The video of the gas door in the bed is was satisfying to watch. Great idea. Thanks for sharing.

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

john, if you need help with tools or anything stop up

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

Thanks Jim. I appreciate your offer to help out. I have some other work to drop off at the shop. Let me see what the shop can do.

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

John,
If you don't have any luck getting something bent up, let me know I have a piece of rear bed floor metal I bought to repair the exact hole in my floor ( mine was for a camp table I believe). I would be more than willing to cut you off a section the shipping from my place shouldn't be that much. As far as the ribs matching up I'm not sure haven't gotten that far on mine.

Bill

Re: Suggestions needed: Repairing a cut hole in floor (rear)
 

Thanks, Bill. That would great if you could trim off a small section. I'll reach out to you via PM with details.