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: