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Looking for guidance installing a new fuel door/flap SPRING...

1617350


Does the spring need to be inserted into both holes/attachment points before the fuel door is installed or is there a method to install the spring while the door is in place? Is the replacement easier if the fuel tank is removed?

Additionally, information on door rivet installation and/or other professional fastening methods such as bolt & sleeve would be helpful.

If there is a link already to this subject it would be greatly appreciated.

- Thanks!
 

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Looking for guidance installing a new fuel door/flap SPRING...

View attachment 1617350

Does the spring need to be inserted into both holes/attachment points before the fuel door is installed or is there a method to install the spring while the door is in place? Is the replacement easier if the fuel tank is removed?

Additionally, information on door rivet installation and/or other professional fastening methods such as bolt & sleeve would be helpful.

If there is a link already to this subject it would be greatly appreciated.

- Thanks!
Hi Mark. I have to do this job also on my project GT. I plan to install the rubber buffers and the plastic lip surround and further protect the paint, both body and flap and then do the rivets using repro rivets from Classic Alfa or others See MI015 GT & SALOON FUEL FLAP HINGE RIVET

Looks like the top rivet flange is up maybe bottom is opposite and there are no washers shown in the Parts book. But you probable have another car handy to look at and can comment.

Classic Alfa also has other repro parts for the fuel door area. see page bottom at the above link.

I would then fiddle in the spring having perhaps made a reverse hook from coat hanger wire or stronger if need be to get the spring ends in place. A reverse hook is a hook used for pushing rather than pulling.

ciao

Ken

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1617370
 

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Hi Ken,

I purchased all the original parts already. However, the new spring is very strong and I don’t believe it can be installed in the little holes with the door in place. I thought perhaps someone has done this a couple times and had some tricks. It looks like it’s going to be a two person job to install, one person installing the spring and then holding the door in place while the other installs the rivets all while not damaging the paint which I have covered with tape.
 

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I can give you my simple two step approach to getting the fuel flap to stay closed

  1. Spend 3 (or more) frustrating hours trying to get the spring attached. A pro once told me this could be a days work
  2. Give up, go indoors and get a few small, thin strong magnets, position them on inside of fuel flap. Adjust magnet position so flap positively clicks closed but is not so strong that you can't actually open it. It has worked a treat ever since.
 

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I just did this job on my Giulia Super. First of all, I got new rivets from Classic Alfa, but realized I didn't have the correct or suitable pressing tool to press them in place. Very limited availability..
Instead, I modified the rivets by drilling a 2.5mm hole, grinded the top of the rivet down slightly, and then used a 3mm Torx screw to lock the rivet in position. Works great. Finally, I attached my old, slightly tired spring, by using a loop of steel wire to pull it into place. No issues whatsoever in getting it in place. Opens and closes as designed with a good fitting.
 

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I just did this job on my Giulia Super. First of all, I got new rivets from Classic Alfa, but realized I didn't have the correct or suitable pressing tool to press them in place. Very limited availability..
Instead, I modified the rivets by drilling a 2.5mm hole, grinded the top of the rivet down slightly, and then used a 3mm Torx screw to lock the rivet in position. Works great. Finally, I attached my old, slightly tired spring, by using a loop of steel wire to pull it into place. No issues whatsoever in getting it in place. Opens and closes as designed with a good fitting.
Yes using a small gauge wire to pull a spring into place is a technique I have used. Not for this application that I recall but for other awkward springs

Ken
 

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Discussion Starter #7
I can give you my simple two step approach to getting the fuel flap to stay closed

  1. Spend 3 (or more) frustrating hours trying to get the spring attached. A pro once told me this could be a days work
  2. Give up, go indoors and get a few small, thin strong magnets, position them on inside of fuel flap. Adjust magnet position so flap positively clicks closed but is not so strong that you can't actually open it. It has worked a treat ever since.
Thank You - Yes, magnets are a nice and simple alternative but I'd like to keep the installation original as Alfa Romeo intended.
 

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I am thinking that when I get to this I will grind a flat on an appropriate sized ball bearing and glue or braze to a vice grip pliers and use the force of the vice grip to expand the aluminium rivet. Maybe this weeks first project. I'll take some pictures.

Ken
 

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I am thinking that when I get to this I will grind a flat on an appropriate sized ball bearing and glue or braze to a vice grip pliers and use the force of the vice grip to expand the aluminium rivet. Maybe this weeks first project. I'll take some pictures.

Ken
I drilled and taped the original rivet for a stainless button head
 

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Discussion Starter #11
The spring is what I was asking for tips... the only way I can see how to install the spring is like I said... putting the spring in the body & door holes prior to the rivets and with two people working together, one holds the door with the spring installed, lines up the door, and other person to installs the rivets
 

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The spring really shouldn’t be an issue. As I said, easy to install after the door is in place with rivets and all. Attach spring to body, pull to flap using a wire loop. It sounds like you have a too heavy duty spring for this purpose..? A small, as the original, spring is good enough
 

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The spring really shouldn’t be an issue. As I said, easy to install after the door is in place with rivets and all. Attach spring to body, pull to flap using a wire loop. It sounds like you have a too heavy duty spring for this purpose..? A small, as the original, spring is good enough
Unfortunately, the painter damaged the original spring removing the fuel door, don't ask me how, so I purchased a spring from Classic Alfa and yes, it seems much stronger than the original. I understand your method, and I appreciate the advice, however, the angle of the bend in the new spring negates pulling the spring with a wire. The spring will not go into the holes if pulled horizontally and must be tilted for insertion.

I have installed the spring with the help of my friend.
 

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For those interested in such things.

I compared some reproduction fuel door parts from Classic Alfa to some removed original parts. The original parts were removed from my 1975 1600 GTj. Earlier years may vary I guess.
DSCN8825.JPG
DSCN8826 - Copy.JPG


The spring wire diameter and number of turns are the same, the hook orientations are the same at 90 deg to each other, the hook shapes vary slightly. NOTE, the same means here more or less.

The rivets have some variations as noted in the pictures. The diameters are the same more or less.

Ken
 

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Mark. It's a pain ! but I recently installed the spring by removing the large rubber gas filler neck boot, accessing the rear of the gas filler door from the trunk interior. Using a pair of long needle nose pliers; I located the spring on the chassis tab and pulled on the spring to make it engage with the door tab. Took maybe 13 failed attempts and I cursed the god of springs as many times.
 

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Discussion Starter #16
Mark. It's a pain ! but I recently installed the spring by removing the large rubber gas filler neck boot, accessing the rear of the gas filler door from the trunk interior. Using a pair of long needle nose pliers; I located the spring on the chassis tab and pulled on the spring to make it engage with the door tab. Took maybe 13 failed attempts and I cursed the god of springs as many times.
Thank you so much Biscione! My installation thoughts exactly and I believe your method is the standard method. However, after less failed attempts than you, I worried about damaging the surrounding paint of the fuel door area and/or the door itself. I decided to pull the fuel tank, giving me the opportunity to clean and powder coat and install the fuel door with help from a friend.
 

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Mark. It's a pain ! but I recently installed the spring by removing the large rubber gas filler neck boot, accessing the rear of the gas filler door from the trunk interior. Using a pair of long needle nose pliers; I located the spring on the chassis tab and pulled on the spring to make it engage with the door tab. Took maybe 13 failed attempts and I cursed the god of springs as many times.
On other applications, this is where I have found the wire pull method or the reverse hook push method to work rather than risking the slipping off of the pliers method. Maybe in some cases a third hand on pliers to finely direct the spring into its place is helpful.

K
 

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Discussion Starter #18
On other applications, this is where I have found the wire pull method or the reverse hook push method to work rather than risking the slipping off of the pliers method. Maybe in some cases a third hand on pliers to finely direct the spring into its place is helpful.

K
- Easier said than done Ken
 

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I installed my fuel door today. All by my self. Pretty easy with the right tools and access.

See how here.


Ciao

Ken
 
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