[kengta]

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

 

[kengta]

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

 

[kengta]

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

 

[kengta]

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

And the spring, what did you do.

Ken

 

[kengta]

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.

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

 

[kengta]

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

 

[kengta]

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

See how here.

Re- Attaching a Fuel Door After Paint

Following another discussion else where I did my Fuel Door re-install today. First I installed the 2 rubber bumpers and the plastic surround on the opening. Then I protected the paint around the opening and completely protected the door with paper and tape. I decided to use the original...

www.alfabb.com

Ciao

Ken

 

[kengta]

what are "CA rivets"?

CA= Classic Alfa. They sell repro rivets. Look above here or in my thread on this topic for photos and comparison. Re- Attaching a Fuel Door After Paint

Ken