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Old 11-09-2017, 05:10 AM   #1
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1986 34.5' Airstream 345
Londonderry , New Hampshire
Join Date: Mar 2017
Posts: 215
Fixed my gas filler door.

My gas filler door had a broken hinge. The 1/8 inch stainless rod
that forms the door pivot had corroded so bad that one side had broken
off. The other side was very hard to move and would likely break off
as well. The door was wobbly and would not shut properly.

I managed to get the door out by bending the rod. To get the pieces
out of the door I had to cut the rod in two. I could pound the rod out
of the door hinge pivot points but it took some pretty heavy blows with a
hammer and punch. Be sure that you support the door pivot points
when you do this. I had to do the same thing for the broken off piece
in the filler housing.

After getting the broken stainless rod parts I tapped the holes in the
door with a 8-32 tap. Perfect fit, no drilling necessary. I got 2
8-32 X 3/4 Allen head bolts from Home Depot. I filed down the
last 3/8 of an inch of the threaded section to 1/8 inch in diameter.
This is the point where the threads are no longer visible.

I used my lathe for this but you could use an electric drill in the same
way. Just spin the bolt and use a file to remove the thread.

Here is the result:
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Pete.
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Old 11-09-2017, 05:21 AM   #2
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Good job, Pete! Probably better than new!

(Looks like something this handyman would come up with... )
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Old 11-09-2017, 05:47 AM   #3
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1986 34.5' Airstream 345
Londonderry , New Hampshire
Join Date: Mar 2017
Posts: 215
Quote:
Originally Posted by PaulnGina View Post
Good job, Pete! Probably better than new!

(Looks like something this handyman would come up with... )
I am the sort that has to have everything working properly!

Pete.
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Old 11-09-2017, 10:08 AM   #4
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1984 34.5' Airstream 345
Foothill Ranch , California
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Nice!
Good solution!
FYI, a cheap aftermarket locking cap for a Suburban fits, and helps keep the precious liquid in your tank! I had my Pickup siphoned in storage of 20 gallons!

I actually hate my gas door.... its top hinge is just a PITA.
One mod I would love to do is change it to front hinged and add a simple door latch that could be popped from inside the bedroom area. Of course, if they really want your 80 gallons they can cut the filler pipe....
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