Mine was change with the tank in the car, they carefully cut a piece out to make the hole above the tank big enough, then made a bigger blank, worked out much cheaper at the time. Would be even easier now I have no interior to speak of.
If anyone is interested I have all the original Lotus release notes for the MY2010 Lotus Exige Cup 260 which specifies everything the cup 260 had tweaked over standard.
Weirdly, there has been an access plate above all the Elise chassis car’s fuel pumps, all of them too small to get the pump out of. When asking the Lotus field engineers why would you do that, the reason from the chassis guys was that a hole large enough to get the fuel pump out of compromises the chassis strength.
Who knows if this is the truth, but it seems weird not to make it larger, just to piss everyone off!!
As another little nugget of info on it, have seen a few side impacted cars where the top of the tank plate is deformed. Always right next to the fuel pump access hole.
Sounds plausible, hence why I’d rather just leave things intact and drop the tank without cutting, unless I could squeeze my hands in enough to remove it, which by the sounds of it, would not be an easy task.
S1 was round. Fitting the electric connector to the pump was painful, as who ever drew the hole in the chassis didn’t talk to the guy that drew the tank/pump very much. This lead to the fuel pipe fittings being offset to the side of the hole. And the electrical connector not under the hole, but under the chassis to one side
There is a trick to it. But does tend to remove a large amount of skin. Small hands help. Which I don’t have
I’m guessing the Toyota hole resolved this by making it slightly larger, to avoid chassis and fuel tank man having a bad day.