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Clear Fuel Door....what if??

3.8K views 40 replies 22 participants last post by  Tuscani2  
#1 ·
Ok so i have been tossing around the idea of making my own clear fuel door, since they are no longer being produced on the market. So here is how i am starting, so this is a VERY rough fist try, i figured out the basics, what i will be doing is using some high grade Lexan plastic, so for one it will be more resistant to weather. So what i did was free hand cut a round piece from a scrap piece i had here, just to try i out, and i had a spare fuel door lying around, so after cutting out the circle (no perfect) i heated it with my heat gun and curved it to fit. The next one i will be doing will be cut with a proper 4.25 inc hole saw for the proper diameter, and it should look mint! PLEASE KEEP IN MIND THIS A ROUGH FIRST DESIGN.

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#10 ·
lexan is bloody awesome stuff, it machines sooooooo nicely, it can be a little expensive though, but I suppose we were buying good sized blocks of it rather than a thin disk
 
#11 · (Edited)
how about resin casting? like, a silicone mold and using clear resin with options for dyes to tint the resin?
i think that'd look cleaner than a lexan one because since lexan is clear, it'll show all the gluing if you use any glue whatsoever
it is kinda expensive to start, but if lexan really is that expensive, then the resin route would save costs if you intend on making more

all it is, is re-molding your stock gas cap. i can post a link to a molding tutorial
 
#13 ·
Very nice dude! If I still had my tib I would def be putting money in your pocket lol
 
#14 ·
Hmm, you need to keep this thread updated so that I can see how much money to send you for one in the future, haha. This plus my new method for getting things wrapped in carbon fiber will equal a complete win!

-Brian
 
#15 ·
Yeah a CF version would look nice too....but i want to start with this version, then see how things turn out, i'll post a little video as well so you guys can get the whole view of it.
 
#22 ·
ok so here is a bit of progress, a perfectly shaped circle, now installed. the issue i have had is trying to glue it, i have tried 3 different types of glue including epoxy and nothing seems to work well, so i decided to use small screws, so for now it works, but i would like to replace the screws with a "FLAT" style screw so it looks flush, i have seen them before, i have to pick some up.