I started looking into the possibility of retrofitting a coupe fuel door on my convertible. I talked to Michael at XVIPERS which carries these doors at a much better prize than the dealership is asking for and in spite of all that’s been said about Michael here on the forum, I found him to be a (for the 4th time) pleasure to do business with. He then referred me to Mark Jorgensen (nice guy) from WOODHOUSE who had retrofitted a Coupe fuel door on a Convertible. He was very kind taking the time to explain what he had done. Once I got a visual on the process I decided to tackle the job myself. This may not be for everyone since it involves trimming of the panel without being able to return to stock. All I can say is that once I saw the results I see no reason to.
Parts;
06’- up coupe fuel door.
5 Allen head bolts (Included w/door)
Coupe fuel filler neck (mount) housing
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Tools I Needed;
Drill motor
Drill bits 1/4, 3/8
1” Rotary file
2” Sanding disk
90 degree Dotco motor
Allen wrench 5MM
Phillips ***** driver
1/4" drive 12mm socket
1/4” ratchet
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I’ll try to keep it as simple as possible.
Start (Mask as req’d for protection)
1. Remove RR wheel
2. Remove aft wheel liner
3. Remove fuel door (2 T30 Torx bolts)
4. Remove fuel cap. (Protect/cover with clean shop towel)
5. Remove filler neck (3 Phillip screws)
6. Remove filler neck housing (4 Phillip screws)
Trimming of panel (Take your time)
7. The raised fuel door mounting portion on the panel will be completely trimmed off to allow for new door to nest flush into position. Touch up with paint after trim is optional since it will not be exposed.
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Locating new fuel door.
8. Remove the 2 aligning pins on back of fuel door.
(Convertible panels do not have pin alignment/locating holes)
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9. Insert allen head bolt in top right hole of fuel door and into the existing top right hole on panel. This is the only existing hole that is used on new door for alignment/installation (hole depicted directly above control arm bolt). Center the fuel door with panel's fuel door cut out(even constant gap) and drill a 1/4” hole diagonally (kitty corner/bottom left) from alignment hole.(hole depicted directly below flor jack).
Note: Opening noted aligning hole may be required (3/8) for additional play/adjustment. Protective tape removed for locating/aligning purpose.
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10. Install filler neck housing (coupe) to panel and fuel door with allen head bolts secure/tight in place. Spot drill only the (3) remaining holes.(recheck alignment first)
11. Remove fuel door & housing and drill thru remainder of spotted holes on panel.
Note: Bottom right hole may break out at the edge of trimmed area. The hole will remain functional.(hole depicted directly below connecting rod).
12. Reinstall filler neck housing and fuel door assembly (5 allen bolts) and check for flushness around periphery of door. Remove and Trim casting as required at mating points to achieve flushness. Repeat this step as required.
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13. Replace by repeating steps 1-6 in reverse order and you are done. I installed the grounding wire on a bolt connecting the panel and bumper together using a hex nut. Brewsky time.....
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Here is a link to additional pics. Anyone in SoCal area wanting to do this send me a PM>
Alpine pictures from cars photos on webshots
Yowsers at those prices I am just going to discard my intended design feature because the purchase price in no way justifies the kind of effort that I am looking to put into it... the only way that would function for me is if I can borrow a coupe fuel door from someone and then send it back once my goal is achieved.
