I looked at alot of cars at the dismantler but the round gas cap holes are usually 5" diameter to allow you to stick your hand in. The smaller ones like on the early Rabbit have a flange to mount the gas filler.

thats stamped and it takes a large metal press to do it.

Have you tried with a hammer and dolley to make the first crease, then on the other side to finish it off? (all the way around the hole..)

It would be a lot of work..

I bet there all stamped from the factory....

Maybe a 4in dia round pipe, and a 3.5in dia round pipe 4 inch on the bottom, 3.5 in on the top, Hammer down on the 3.5 in pipe... for the flat portion, move the 3.5in pipe to the other side and hammer down till flat?

A solid 3.5in dia pipe would be best.. if you could find it (probably a lot of money.. lol

Never thought of having to make that..

Good luck!

Make an inside and out side die set out of 3/8" steel. Use a 3/4" or 1" bolt (big bolt) and an impact to pull the two parts together. Or just use a hammer and dolly....

make a sheet metal ring the same dia as the hole, or cut it from something cylindrical the right size...weld and grind

I did both methods, this picture welded ring , the other I did hole saw and hammer and dolly but did a shorter lip about 1/2inch

other

rear??

Whats that go to? Oil?

peterson oil tank,different

I am with Rick, a belling tool is ticket. If you have a lathe you can make one, or farm it out. There is a bodywork book that covers this pretty well but I can't remember the name of it at the moment.

QUOTE (sixnotfour @ Dec 14 2005, 10:52 PM)

peterson oil tank,different

Cool, but don't ever stop for fuel in Oregon. Some pump monkey will fill it with gasoline!
-Ben M.

how is the gas cap kit from martin baker (mentioned in the spanish 914 gt) thread set up? does it require reshaping the hood?

You can always go to a junk yard and have them cut the thing out of a car, then weld it up.
Or do this like i did to mine.

make a wooden female form. then take a hammer and hammer for the rough shape and then very carefully smooth it out with a hammer and dolly.

Hi Felix,

If the recess is not too deep, you could clamp a pipe underneath, and use a hammer with a corking or caulking tool...just a piece of wood or aluminum shaped like a dull cold chisel. You would gradually tap on the corking tool held against the sheetmetal, and the pipe below would define the circle. Then form the flange with some pliers or a crescent wrench...finish off with hammer and dolly. If the hole is deep..say over 3/8" you may have a problem with the area around the hole losing some of its shape, because you may need to stretch the flange a little....

John www.ghiaspecialties.com

Take a look at this one.

I think with some reall good measuring, you could make this work...not the way it works on a motorcycle tank, but the idea...

Im thinking that the cap should be accessible from the outside, but look flush...try to blend it in.

Hotch Gas cap

Rich

This fits my theme better

Oooh, very neo

QUOTE

This fits my theme better

ooooh, nice...what's that from?

Tequipment

QUOTE (iamchappy @ Dec 15 2005, 09:55 AM)

You can always go to a junk yard and have them cut the thing out of a car, then weld it up. Or do this like i did to mine.

i like that clean look, chappy. did you actually do that, or is that a "photoshop weld?"

That will get stolen if you park on the street, first night!

you know...the more I was thinking about this...

I would go to the local steel supplier...have them make you a ring out of round bar stock...

Cut the hole, take or clamp the ring right where you want it...

Heat the steel and hammer it around the ring...

You might even just leave the ring...

It may or may not work..just seems to be a good way to get a perfect ring, with the right diameter, then you just need to bent the metal over it...

If you used pipe, you could probably weld it right to the under side of the lid, cut out the metal in the middle...weld/grind/sand till smooth, and leave the pipe ring in place...it might look smoother that way also...

Rich

I just cut the hole in the lid and mounted the fuel door to a piece of steel mounted to the inside of the lid.

I considered gas doors (and there are alot of them) but I want to show the new GT cap design, probably sticking out slightly. The hood will be featureless without the headlight cut-outs.

Theft is a consideration but it does have a "chain" and I could always replace it with a standard cap when I'm away or on the "east" side...

914-8

Felix, I'd be more worried about people trying to sypher fuel and dripping on the paint, or adding water to the gas in a prank or jelousy...

Will you be driving it on the street much?

QUOTE (Andyrew @ Dec 16 2005, 12:18 PM)

Felix, I'd be more worried about people trying to sypher fuel and dripping on the paint, or adding water to the gas in a prank or jelousy... Will you be driving it on the street much?

syphon....

I'll have to find a locking gas cap then...

Hey do people steal gas now??? I remember people doing that in the 70's

This is how mine looks with the door open.

I topped off the stock cap with a wheel centercap.

Nice touch, how about a clear door?

QUOTE (jonwatts @ Dec 15 2005, 11:59 PM)

Tequipment

$135 for a friggin' gas cap!?!

QUOTE (Buzzard1 @ Dec 16 2005, 03:29 PM)

QUOTE (jonwatts @ Dec 15 2005, 11:59 PM) Tequipment $135 for a friggin' gas cap!?!

yeah but you get a velour bag, sticker, and certificate too!

QUOTE (iamchappy @ Dec 16 2005, 11:50 AM)

I just cut the hole in the lid and mounted the fuel door to a piece of steel mounted to the inside of the lid.

sorry so dumb, that's just a door then.

what vehicle did it come off of?

Do a search on ebay for fuel door take your pick, Mine was for a Mustang.

This lid looks like high security manufactured for the 914. Only $78

top...

That would look right at home on a porsche.......









tractor

QUOTE (jonwatts @ Dec 15 2005, 09:59 PM)

Tequipment

that thing cost a really, really, really shiney penny crazy neo...you have entered the matrix

QUOTE (dlo914 @ Jan 14 2006, 12:41 AM)

QUOTE (jonwatts @ Dec 15 2005, 09:59 PM) Tequipment that thing cost a really, really, really shiney penny crazy neo...you have entered the matrix

Am I the "one/neo"?

QUOTE (iamchappy @ Dec 15 2005, 06:55 AM)

You can always go to a junk yard and have them cut the thing out of a car, then weld it up. Or do this like i did to mine.

Where did you get that access door? Donor vehicle or aftermarket?

QUOTE (jasons @ Jan 14 2006, 01:15 PM)

QUOTE (iamchappy @ Dec 15 2005, 06:55 AM) You can always go to a junk yard and have them cut the thing out of a car, then weld it up. Or do this like i did to mine. Where did you get that access door? Donor vehicle or aftermarket?

he already stated eBay, there are dozens of flavors CF, billet, polished...