Hi folks.

 

I'm gonna replace the filler tube on my '99 Outback this weekend. The 3 screws that attach the tube to the quarter panel are rusted tight.

 

I was thinking about cutting them off w/ a dremel tool, but that will cause some sparks. Any chance that would cause fuel vapor to go blammo?

 

Thanks.

 

UH... PROBABLY!!!!

 

Don't be a Darwin Award. I wouldn't try it.

 

What about drilling the heads out?

Sparks using a dremel tool may be okay, if there is no gasoline vapor present. The vapor is what not to mess with, because that is explosive. If any chance of gas vapor, then don't use the dremel.

Sounds very risky. Even if the tank has been empty for some time there is likely to be some vapor in there nonetheless. Possibly a nitrogen purge on the tank might make it safer but caution would be in order no matter what is done.

I have to agree with the others. Being a long time and frequent Dremel user (I hope the inventor is rich and famous beyone belief) and hazardous materials technician, the cutoff wheels still make enough sparks to ignite gasoline vapor. The flash point (temperature that causes ignition) of gasoline is low enough that it takes a minimal amount of heat to get it going. The vapors have an explosive quality so they are much more dangerous than the liquid fuel itself. The vapors also ignite much more readily than the fuel will.

 

Drill them out.

Whenever I do them, Before I even put a screwdriver on them. I take them out first with an impact driver. That always works for me, unless someone already butchered them. Then you can drill them out, or, I've used carbide burr drill bits with success too. They don't really make any sparks, and eat up the screw head pretty well.