Thanks, I cut mt hole, was a bit off, but think it will work. My pump '94 is a bit different, and remember now that I got one with the generator tube that I never used.
I did the 'drill many holes method, with a broken drill bit chucked to allow about 3/8" so I wouldn't hit anything critical. It was too far to drive to get drill stop collars or to buy a sheet metal nibbler to use one time. After measuring and cutting out carpet and removing cabinets it was a bit over an hour.
I'm hoping this does it.

 

After being stranded with my 2002 E250 van pulling a mini excavator on a trailer, I decided to install a cover in the floor to access the electric fuel pump assembly. I started by measuring the location of the fuel pump assembly location from underneath the van. The cut was made with a 6" hole saw but it wasn't big enough to get the pump out. The hole was enlarged with a dremel cutoff wheel. The floor thickness is approximately 16 gauge and is steel. I only had 14 gauge sheet onhand so that is what I used to fabricate the cover. I had planned on using my powered rollers to form the ribs but the wheels hadn't arrived yet from Milter Bros. As a result, I formed the ribs with a combination of a metal brake and hammer/dolly. I attached the cover to the floor with 8-32 flat head screws, rivet nuts and RTV. I also sealed the cover with a sheet of plastic and hot glue. I hope that the photos with save someone else some time!

 

Hey man that looks nice, I would love a cover like that, my 99 still has the factory pump.

 

That is a nice bit of sheet metal fabrication---nice attention to detail.

However without offense I would NOT cut into my own van's body like this especially if no steps are taken to adequately protect the exposed raw metal edges from rust. Having replaced a fuel pump in a 2003 the more traditional way of removing the tank I discovered a hole being worn in the tank from the straps. It wasn't leaking before the pump failure however had it not been discovered no way knowing when it would have become a huge issue. Lucky for me the shop doing the work could and did weld a repair patch in place.

Sure doing it the traditional way costs a bit more as the straps tend to break requiring replacement. Having the tank out allows you to have it cleaned and as mentioned inspected for emerging weak spots. The minor extra expense of this method is well worth the effort if only for the peace of mind.

 

My Pops talked me into cutting the floor. At first, I didn't like the idea of cutting into the floor on something I purchased new. But, the argument was persuasive because the truck is now 20 years old and getting towed while pulling a rental trailer and equipment made for a terrible day. The tow truck operator made things worse by dragging the bottom of my stainless ball into the pavement and pulling the front control arm enough to bend the steering. Anyway, the bare metal of the hole was prepared and painted as well as the fabricated cover. I now have a spare pump in the van that I can easily replace if stranded again.