Fuel door falling off fix

[mkwpros619]

Here is a video I made on how to fix the fuel door / gas cover from falling off.
https://youtu.be/nc6nCc1m-8k

[gsxrdoug]

I might do it a little different but you got me thinking and I do worry about that door flying off and being gone forever.
Thank you.

[20Baja06]

I’d probably use some slip-on nuts and simply run a bolt through like the original clips. Something like these nice options from McMaster-Carr, for example.

I didn’t realize this was an issue so I’ll definitely be looking into it in the near future.

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[Trunc]

Mine fell off just the other day. The plastic pin on the forward side of the cover broke. I cleaned the surfaces and squeezed a small amount of silicon in and around the pin. This made “cap” on the broken pin so it will not come off. Silicone lasts virtually forever. A simple, cheap, clean fix.

[Trunc]

PS- I suggest give the cover a little tug at each fuel up to find the problem before it falls off. I ended up searching the roadway for 1/2 hour before I luckily found it.

Mine fell off just the other day. The plastic pin on the forward side of the cover broke. I cleaned the surfaces and squeezed a small amount of silicon in and around the pin. This made “cap” on the broken pin so it will not come off. Silicone lasts virtually forever. A simple, cheap, clean fix.

[anarchy1024]

I’d probably use some slip-on nuts and simply run a bolt through like the original clips.

I ended up doing something similar, just with regular nuts and bolts; I didn't want to cut the plastic door cover in any way.

1. Find nuts and bolts that fit, and trim the bolts to length. If you find a nut the right size, it'll fit snug inside the plastic "stand-offs" and not rotate freely.

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2. Add a bit of glue or something to hold the nut in place, so it doesn't fall out while trying to install it.

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3. Screw the bolts in from the outside as normal.

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[mark40]

I've used the zip tie method since acquiring my '06 in 2014.

[20Baja06]

The flaw with my plan to use the slip-on nuts was failure to consider that the “stand-offs” taper towards the mounting hole, meaning the plastic is narrower at the top than the bottom. The slip-on nuts I had on-hand were too long and would have required trimming along the corners that would be on the cover side of the stand-off.

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I still like the idea but I didn’t have a great way of trimming spring steel so I replaced the original plastic push-in clips with some new ones I had in the drawer.