C5 Gas Filler Relocation

[GB Vette]

Unfortunately I didn't take any pics while I was doing this mod. It really was a spur of the moment type thing and I have about 3 hours tied up in the whole thing so far. As far as costs go I've got less than $20 in it not counting filler, glass, primer, etc.

Here's some pics I took after the fact and I'll try and walk you through what I did.

I measured the bottom of the stock gas filler surround and found it to be about 4" in diameter. So, I knew I needed something about 4" in diameter to use for my custom fill mount.

I found a piece of 4" thin wall PVC sewer/drain line and decided this would work for the collar.



I then used a cutting wheel on the Dremel to cut out the bottom of the stock surround.



I then cut a 6" piece of the 4" PVC pipe and beveled the inside of it on one end. I cleaned up the outer edge of the stock bottom piece I had cut out and glued this to the beveled end of the 4" PVC using Plastic Weld epoxy. I've used this epoxy before and have had good luck with it.

I knew I had to keep the fill tube as high as possible in the door jam to maintain a downward angle on the fill line going into the tank. I drew a 4" circle on a piece of paper with a compass and cut out the circle to use as a template.

I held this template up on the door jam and determined the location for the fill tube. I marked the center of this location with an awl through the center hole left by the compass point in the paper. Using this center mark as my guide I used a 4 1/4" hole saw tilted downward at about a 15 degree angle to cut through the SMC and into the steel framework. I cut into the steel as far as I could before the hole saw bottomed out. I used a cutting wheel on the Dremel then to complete this initial cut.
Here's a couple of pics of the plug the first cut produced.





I continued cutting and trimming with this 4 1/4" hole until I reached a depth of 2 1/2" on the horizontal centerline. This 2 1/2" depth was to allow for the gas cap height. I then beveled the the hole in the door jam. My next step was to cut two holes in the back wall of the framework to clear the filler neck assembly. I cut these two holes with a 2" hole saw and trimmed the opening as required with snips. After all of the cutting and fitting was done I put everyting together with 3M panel bonding adhesive and let dry overnight. The next day I cut the excess 4" pipe protruding into the door jam off with a cutting wheel on the Dremel. Sanded the pipe and the area around it smooth and filled with SMC filler.

Here's a shot looking upwards showing some detail on how the filler neck assembly looks in place.



And another shot looking down on the filler.





I've added some vinyl edge trim to this cut opening since the pic was taken to help prevent any chafing that may occur.

I added a pre-formed 90 degree hose to the fill line because the stock one wanted to kink up when I tried to connect it to the neck. Also had to relocate the screw for the ground strap.

Here's a straight on shot. Index the mounting holes like this to keep the vent/return line lined up properly.



I do hope this helps and makes things a little easier for you

[DropTheTop]

I just love this mod! You are the man.

[Culookin]

So when can we start on mine

[WKMCD]

Originally Posted by DropTheTop

I just love this mod! You are the man.

I agee absolutely! Very cool.

[Lowcash]

I do like this location a lot better than the rear light idea initially considered.

[thegreenman]

Sweeeet. :Thumbsup:

[Sneaks]

I love this mod. Not only is it just plain cool as all get out, it also eliminates one more thing that can go bad.(fuel door opener)
Nice job Gary!

[Dougzilla]

Has to be one of ther most unique mods I have seen. Do you get the smell of gas in the cab after filling ot up ?

[C5 BEARSFAN]

how many times do they walk around the car at a full service station looking for the gas tank

This is a really cood mod Gary
Great Job

[[email protected]]

That's a cool looking mod!

[Neutron]

Amazing.

[Garb55]

Originally Posted by Neutron

Amazing.

[YELLOHH]

Originally Posted by Dougzilla

Do you get the smell of gas in the cab after filling ot up ?

[GB Vette]

Not at all! The filler is located between the inner and outer door weatherstrips and has not created any problems with fumes and/or smell.

[Garb55]

Originally Posted by Garb55

"GREAT WORK"HAD TO COMMENT AGAIN!

[Bluezey]

Very Kool ! !

At first I thought that you were going through a taillight


Bluezey

[wwomanC6]

Sweet!

[YELLOHH]

Originally Posted by GB Vette

Not at all! The filler is located between the inner and outer door weatherstrips and has not created any problems with fumes and/or smell.

Hmmmmm....

[MYSCZ06]

nicely done shaved door handles and relocate this cleans it up nicely! adding it to the list!

[persys73]

Originally Posted by [email protected]

That's a cool looking mod!

Great I dea... I would like to know how exactly did you shave the original....