Back around 2013, we were on a trip, and the RV died. The fuel pump relay had burned up. I believe this was a precursor to the pump itself dying. Within a year, the pump itself burned up. When I say "burned up", I mean it had melted the metal of the pump. When this burned up, it also burned up the inertia cutoff switch. This was the OEM pump. It was replaced in 2013. The shop that did the replacement put the wrong pump in. Long story short - Airtex's web site did not take into account a part number change in September 1990 so they gave out the wrong fuel pump part number. Made the gas gauge run backwards. So, I had to have it replaced again with the correct one (E2060S).
This pump probably failed 3-4 years ago but I never knew it or suspected it until I got a digital fuel pressure gauge installed on the fuel rail and caught the failure in the act. I also installed ammeters on the line to the high pressure pump and at the inertial cutoff switch (I would prefer to have installed it at the in-tank-pump itself, but I cannot access it). The pumps are getting the correct amount of voltage and draw the proper amount of current (when the in-tank pump is running).
I believe the problem is simply that Airtex pumps are not quality pumps.
Anyway. Floor time. I'm thinking of cutting out a square opening, and fencing the perimeter with 2x4 or similar framing structure. This will give the hatch and surrounding floor something solid to sit on so there is no give when you walk across it. The removable plug/hatch will be floor foam with sheet metal on top of that, and the vinyl on top of that. I will drill small holes around the perimeter of the vinyl to allow flat-head screws to recess down into the vinyl and bottom out on the sheet metal. This way there will be no screw heads protruding up from the vinyl. I was not going to bother with a hinge as hopefully I won't be removing this hatch often. There will be another piece of sheet metal down on under the floor foam on the bottom "hull" plate of the RV, which I'll install with regular sheet metal screws. This will support the hatch and anyone standing on the hatch. When the hatch is removed, and the bottom hull plate remove, I should have access to the top of the fuel tank.
