Gas Filler Door Smoothing - DIY

I decided to test a new primer for this job, Endura EP-2C.



Had a little troubling spraying it, getting used to the consistency.

This was the first coat, 2nd coat turned out horrible. I will wait to see how it dries to see if it will require a 2nd coat, or high build.

As we wait (8-12 hours), here is another picture, at least automotive related.

The filler has dried, and we hit it quickly with a DA sander


Using our trusty Dura-Block, we block the filler door until decently straight.


This is our gas door before it recieves primer.



Once again, we must wait until the day is better for primer -- at least we can look at pictures of Angela (RIP). Update when possible.

So, instead of being the typical obnoxious idiot who takes instead of giving to this community, as inspired by the BimmerToad thread, I have taken on this project, of "smoothing" the gas door and removing the finger nub:

Sure, there are many ways to do this, and I did it this way. I am no means a professional.


Gas Door - autobahnparts.com - $10


Using a body hammer and an vice, we pound down the outdent (opposide of indent) :) As we can see, we are left with a little bit of the door that sticks out on the left hand side, where the finger door metal expanded.


Using a 36grit sanding disk on an angle grinder, we remove that outer nub, and clean up the paint a little bit.


Using the 36grit disk, we contiune to remove the rest of the paint, and wipe down the metal with a good wax and grease remover. Beer is essential.


Using a GOOD filler, we put a light skim coat across the gas door panel.



Let filler dry, and look at pictures of Bianca.

More soon.