DIY Fuel Door shaving *pics*

**Mike Diaz** · 12-18-03, 03:03 AM

*This will be moved to the DIY section in 3 days*

As some of you know, I'm doing a lot of custom body work to my 91 Coupe. This is the general idea behind moving your gas cap to the trunk, and shaving the fuel door.

1. Remove the fuel door. Two 10mm bolts. Grind down to bare metal around the fuel door.

2. Remove the fuel cap and the tubes that runs down to the fuel tank. You have to remove part of the inner fender well to get to it. To remove the tube, there are 2 hose clamps holding the tube to a rubber hose leading to the fuel tank.
3. cut a piece of stainless sheet metal to fit in the hole where the fuel door used to be.

4. Tack weld that piece of metal into the hole, grind the tack welds down smooth and then use Duraglass for a primary filler.

5. Sand the Duraglass to a smooth surface, then use a lightweight body filler for the finishing filler. Block sand the body filler until you create a smooth surface. Apply primer to the area.
6. Take the fuel tube and wash the fuel residue out of it (to prevent fire). Cut the big and small tube in half. turn the top part of the tube 180 degrees and tack weld the larger tube back together until it is sealed. It's a good idea to use JB weld or another type of Epoxy sealer on the outside of the tube to prevent leakage. (pics coming)
7. Cut the smaller vent tube so that each end is about 2 inches long, then buy a foot of 5/8 fuel hose and 2 good hose clamps, cut the hose to fit, then fit the hose between the two ends and clamp it down. (pics coming)
8. Fit the fuel tank end of the tube into the fuel tank fitting and find out where you need to cut the wheel well. Mark a square, plug the fuel tank with a damp rag, and cut your hole.

9. Once you have the hole cut, feed the upper part of the fuel tube into the trunk and make sure that the trunk lid bars don't hit the cap or tube.
10. Once your fuel tubes are mounted, you need to cut 2 pieces of sheet metal to fit on each side of the fuel tube to cover up the rest of the hole. slide each piece of sheet metal around the fuel tank tube and tack weld the 1st piece of sheet metal to the inner part of the fender well. Then do the other side of the tube. The fuel tube should still be plugged. It's basically to cover up the space around the fuel tube, this part is really hard for me to explain, I'll get more pics on Sunday.
11. Unplug the fuel tube, twist your cap on.
12. Reinstall the inner fenderwell. You're done!

I'll be updating this thread in a few days, then moving it to the DIY section.

Mike Diaz

tnelson · 12-18-03, 03:07 AM

nice job mike.

RangerJoe · 12-18-03, 03:10 AM

woah....

you should look into shaving the door mouldings...that would be stellar.

**502 MotorSports** · 12-18-03, 03:22 AM

shweet

that is pretty cool Mike

Are you coming back to ATL next year?

**Mike Diaz** · 12-18-03, 03:59 AM

I think Nopi will have to wait until 2k5. My wife just found out she's prego

she's about 1 month right now. She's due in August, and I don't think she'll be up for a road trip.

mYbabYLeGend · 12-18-03, 04:00 AM

wow mike thats tight
and congrats on the baby

**Mike Diaz** · 12-18-03, 04:01 AM

Quote:

Originally posted by RangerJoe
woah....

you should look into shaving the door mouldings...that would be stellar.

I would have done it if I could shave the bumper molding with it. The bumpers are done (you can see the shaved rear bumper in the pics) and I don't want to mess with them. I hope it'll look OK with the door moldings.

Phireant · 12-18-03, 04:48 AM

dang mike when am i coming down to take a look at this crazy ride?!!!

**Mike Diaz** · 12-18-03, 05:03 AM

wanna come out Sunday? I'll be heading out to his house at about 9:00 AM.

mortsayyed · 12-18-03, 06:01 AM

congrats on the baby

Mort

*Thai.95LCoupe* · 12-18-03, 06:06 AM

Congrats on the new addition.... Shaved..

ILOVELEGEND · 12-18-03, 08:14 AM

good job Mike!! I'm assuming that's you in the first 2 pictures..

Congratulations on the Baby! We are also expecting our second one in July next year!
Lots of hard work going in that ride of yours!

ILOVELEGEND · 12-18-03, 08:15 AM

Quote:

Originally posted by Leon Millette
shweet

that is pretty cool Mike

Are you coming back to ATL next year?

Leon, it's good to see you!

**Mike Diaz** · 12-18-03, 08:37 AM

Quote:

Originally posted by ILOVELEGEND
good job Mike!! I'm assuming that's you in the first 2 pictures..
Congratulations on the Baby! We are also expecting our second one in July next year!
Lots of hard work going in that ride of yours!

That's my buddy Chad. He runs Cope's Customs with his father. He's a really good welder, and his father is even better. Wait to you see that we cut my hood in 3 pieces and welded it back together a little different than the factory look. That's my next surprise.

Matt Whelan · 12-18-03, 08:49 AM

So now you have to open your trunk to fill up your gas tank? That is going to stink your car up...

12-18-03, 03:03 AM	#1 (permalink)
Mike Diaz WHAAAAAH! Join Date: Jan 2002 Location: N Canton, Ohio Posts: 10,986 Car 1: 3.5L 1991 LS Coupe 5 Spd Blk/Blk Car 2: 1994 Civic EG Hatch Car 3: 03 Honda TRX400EX iTrader: (2)	DIY Fuel Door shaving pics This will be moved to the DIY section in 3 days As some of you know, I'm doing a lot of custom body work to my 91 Coupe. This is the general idea behind moving your gas cap to the trunk, and shaving the fuel door. 1. Remove the fuel door. Two 10mm bolts. Grind down to bare metal around the fuel door. 2. Remove the fuel cap and the tubes that runs down to the fuel tank. You have to remove part of the inner fender well to get to it. To remove the tube, there are 2 hose clamps holding the tube to a rubber hose leading to the fuel tank. 3. cut a piece of stainless sheet metal to fit in the hole where the fuel door used to be. 4. Tack weld that piece of metal into the hole, grind the tack welds down smooth and then use Duraglass for a primary filler. 5. Sand the Duraglass to a smooth surface, then use a lightweight body filler for the finishing filler. Block sand the body filler until you create a smooth surface. Apply primer to the area. 6. Take the fuel tube and wash the fuel residue out of it (to prevent fire). Cut the big and small tube in half. turn the top part of the tube 180 degrees and tack weld the larger tube back together until it is sealed. It's a good idea to use JB weld or another type of Epoxy sealer on the outside of the tube to prevent leakage. (pics coming) 7. Cut the smaller vent tube so that each end is about 2 inches long, then buy a foot of 5/8 fuel hose and 2 good hose clamps, cut the hose to fit, then fit the hose between the two ends and clamp it down. (pics coming) 8. Fit the fuel tank end of the tube into the fuel tank fitting and find out where you need to cut the wheel well. Mark a square, plug the fuel tank with a damp rag, and cut your hole. 9. Once you have the hole cut, feed the upper part of the fuel tube into the trunk and make sure that the trunk lid bars don't hit the cap or tube. 10. Once your fuel tubes are mounted, you need to cut 2 pieces of sheet metal to fit on each side of the fuel tube to cover up the rest of the hole. slide each piece of sheet metal around the fuel tank tube and tack weld the 1st piece of sheet metal to the inner part of the fender well. Then do the other side of the tube. The fuel tube should still be plugged. It's basically to cover up the space around the fuel tube, this part is really hard for me to explain, I'll get more pics on Sunday. 11. Unplug the fuel tube, twist your cap on. 12. Reinstall the inner fenderwell. You're done! I'll be updating this thread in a few days, then moving it to the DIY section. Mike Diaz __________________ 2nd Gen FAQ \| Newbie FAQ \| Bleeding Coolant DIY \| Manual Trans Flush DIY 3.5L DIY \| Crank-No Start Diagnosis \| How I built My Legend

12-18-03, 03:07 AM	#2 (permalink)
tnelson Pedobear is watching you Join Date: Feb 2002 Location: Oklahoma Posts: 7,636 Car 1: 2002 TL-S, white Car 2: 1992 Corvette iTrader: (3)	nice job mike. __________________ http://www.youtube.com/watch?v=feLqz1udhtY

12-18-03, 03:22 AM	#4 (permalink)
502 MotorSports 502MotorSports.com Join Date: Jan 2002 Location: ATLVILLE Posts: 9,445 Car 1: e39 540i Car 2: e46 325xi \| e46 330i Car 3: S430 iTrader: (0)	shweet that is pretty cool Mike Are you coming back to ATL next year? __________________ The Hotness! Elevate Your Standards.... Legend Mod Money! Jasmyn \| Final e39 Pics \| 502MotorSports MySpace

12-18-03, 03:59 AM	#5 (permalink)
Mike Diaz WHAAAAAH! Join Date: Jan 2002 Location: N Canton, Ohio Posts: 10,986 Car 1: 3.5L 1991 LS Coupe 5 Spd Blk/Blk Car 2: 1994 Civic EG Hatch Car 3: 03 Honda TRX400EX iTrader: (2)	I think Nopi will have to wait until 2k5. My wife just found out she's prego she's about 1 month right now. She's due in August, and I don't think she'll be up for a road trip. __________________ 2nd Gen FAQ \| Newbie FAQ \| Bleeding Coolant DIY \| Manual Trans Flush DIY 3.5L DIY \| Crank-No Start Diagnosis \| How I built My Legend

12-18-03, 04:00 AM	#6 (permalink)
mYbabYLeGend Sexy Member Join Date: Apr 2002 Location: MI Posts: 7,522 Car 1: 91 l sedan Car 2: 94 gs sedan--sold Car 3: 97 sc300 iTrader: (0)	wow mike thats tight and congrats on the baby __________________ RIP ZAK <----master of the unibrow Im carrying Darriths baby -da hass man http://www.acura-legend.com/gallery/file.php?n=169&w=l 91 L sedan- few mods 94 Gs- sold 97 Sc300-stock for now

Remove Advertisements Sponsored Links
The Acura Legend & Acura RL Forum Advertisement

12-18-03, 03:10 AM	#3 (permalink)
RangerJoe werd..... Join Date: Apr 2003 Location: Stillwater, Oklahoma Posts: 6,220 Car 1: 92 LS coupe 5spd iTrader: (4)	woah.... you should look into shaving the door mouldings...that would be stellar.

12-18-03, 04:48 AM	#8 (permalink)
Phireant Lov*n' My Legend Join Date: Aug 2003 Location: north-east ohio Posts: 178 Car 1: 1993 LS Sedan, Cashmere Silver iTrader: (0)	dang mike when am i coming down to take a look at this crazy ride?!!! __________________ Completely stock... I'm a poor college student

12-18-03, 05:03 AM	#9 (permalink)
Mike Diaz WHAAAAAH! Join Date: Jan 2002 Location: N Canton, Ohio Posts: 10,986 Car 1: 3.5L 1991 LS Coupe 5 Spd Blk/Blk Car 2: 1994 Civic EG Hatch Car 3: 03 Honda TRX400EX iTrader: (2)	wanna come out Sunday? I'll be heading out to his house at about 9:00 AM. __________________ 2nd Gen FAQ \| Newbie FAQ \| Bleeding Coolant DIY \| Manual Trans Flush DIY 3.5L DIY \| Crank-No Start Diagnosis \| How I built My Legend

12-18-03, 06:01 AM	#10 (permalink)
mortsayyed Registered User Join Date: Nov 2003 Location: Wisconsin Posts: 141 Car 1: 1991 Acura Legend iTrader: (0)	congrats on the baby Mort __________________ ON ORDER Ranger Joe CAI Stromung Exhaust Bayou Stage II Chip 6000k HIDs 18" Racing Harts Pioneer 9815 HU And more to come... "Yeah actually I get paranoid ~ the stock Legend front looks so good I'm afraid someone will rip it off my car and put it on their Integra or something "

12-18-03, 06:06 AM	#11 (permalink)
Thai.95LCoupe K L E A N M O D™ Join Date: Jan 2003 Location: Roswell, Georgia Posts: 5,345 Car 1: 1995 KA8 R.I.P Car 2: 1997 S14 SOLD Car 3: Millenia S & S14 iTrader: (6)	Congrats on the new addition.... Shaved.. __________________ -1995 KA8 MODIFIED-R.I.P -1997 S14a-SOLD -2000 Millenia S -1995.8 S14a -Holy Rollerz CCC Member- -Inspiration™- My KA8's totaled and still greater than.... Imitatated. Never duplicated.™

12-18-03, 08:14 AM	#12 (permalink)
ILOVELEGEND Registered User Join Date: Jan 2002 Location: Irvine, CA Posts: 1,677 Car 1: 1994 GS Black / Tan iTrader: (0)	good job Mike!! I'm assuming that's you in the first 2 pictures.. Congratulations on the Baby! We are also expecting our second one in July next year! Lots of hard work going in that ride of yours!

12-18-03, 08:49 AM	#15 (permalink)
Matt Whelan Registered User Join Date: Jan 2002 Location: Georgia Posts: 2,855 Car 1: 1992 Seattle Silver LS iTrader: (0)	So now you have to open your trunk to fill up your gas tank? That is going to stink your car up... __________________ 1992 Acura Legend LS Sedan Car name: AL<---figure it out http://www.imagestation.com/picture/...4/fd44ef6e.jpg Modifications GS Rims Acura Gold Emblem Kit OEM CD Changer EDM Corners BMW X5 Xenon Projector headlights Xenarc Xenon driving lights Custom Red/Clear/Red taillamps & JDM Red/orange/Red Taillights 6 color Indiglos Black Mesh Upper Grill

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)

Thread Tools
Show Printable Version Email this Page
Display Modes	Rate This Thread
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode	Rate This Thread: