Any tips on installing a fuel level sensor assembly in a tight space?

I thought you were going to use a hole saw? :-/ At first glance I thought maybe you turned the blade around on a circular saw.

 

I have bought lots of used trucks, I hate buying one that the wiring has been butchered, I would not buy one that the support had been cut up in the cab if I knew it at all, except for parts. just unbelievable and for no reason. A guy could have had the new gauge installed correctly by the time you took the seat out and put it back, and EASIER.

That raised dimpled section where the bolt hales are are major flloor pan supports, it is what stiffens it.

 

That little hole ain’t gonna hurt anything. Good Job. It’s done. Cover came out nice. I’ve watched them do brand new Duallys, on Chevys and Dodges. Talk about a butcher job.Anyone who saw the process, would never buy one.But they cover it all in plastic. Some flathead screws, and undercoating, you’ll never see it. I’ll change stuff, when it’s a bad design, making it easier to do in the future.Theres definitely a disconnect between Engineers and Mechanics. I’ve met more than one, who can’t change oil.

 

It will help that you don't have a seat in it, and that metal is tough, but it is not very thick, and the same thing that makes it tough also makes it somewhat brittle. What will happen is at the squared off corners, it will eventually start cracking, to me even a round hole would have been a butcher job, but it would have lasted a lot longer before the cracking starts.
I have seen many trucks that were never cut develop a crack in the floor of the cab, and in sleepers too, and the cracks just travel from the flexing that they do.