6.1 Hemi 69 Barracuda Fastback Father Son Project
Been slow going this summer but made a little more progress today.
Swapping to a Modern Challenger Fuel door to in place of the stock flip-top fuel cap added the complication of sealing weather or fuel from making it's way into the trunk...
So this is what we cam up with.
We made what is basically a can with a bulb seal that fits against the inside of the quarter panel.
The original fuel fill tube was sectioned to account for the length and angle change needed to accommodate the inset depth of the back of the Challenger fuel door assembly.
The flange of the original fuel filler is sandwiched between the "Can" and the fuel door housing.
Any water from washing or weather that comes in through the door or fuel burps or drips when refueling will drain out the bottom of the can nipple and tubing that will be routed out down between the trunk extension and quarter panel. Most likely will feed a line out through the body plug in the bottom of the trunk extension.
The finished fuel door install looks like this.
This is what the backside looked like before sealing it off from potential weather or fuel finding it's way into the trunk through all the gaps in the door assembly.
The fuel door is not weather tight...
The body of the fuel door body is also not weather tight. Spilled fuel or burped will drain out the hole circled in red below. That is a factory drain hole. I did not want it to drain inside the trunk...
The solution isolates the trunk from weather, car washing, or fuel burps or overfill that could have found it's way into the trunk.
The fuel door snaps into the body exactly as with a new Challenger.
The "Can" enclosure uses a bulb seal against the inside of the QP.
The way is is assembled uses the Fuel Door and the "Can" to pull against each other to compress the bulb seal against the inside of the QP.
The can has a length of tubing welded into the very bottom in order to plumb a drain out of the car.
The nipple on top of the fill tube is the factory vent opening, it will have the original vent tube attached to it.
A small section of filler tube removed to correct the length and angle difference between the back of the Challenger door and the original flip-top cap locations. We will be adding a bracket to the lower section of the fill tube to secure it in place by attaching it to the adjacent wheelhouse bracket.
Really happy with the results. Probably way more work that it was worth but it's done... Almost...
Still have to get the fuel tank installed and it doesn't seem to want to fit without being up against the rear shocks... Ugh!
Will get it up on my lift at home to tackle that...
Been slow going this summer but made a little more progress today.
Swapping to a Modern Challenger Fuel door to in place of the stock flip-top fuel cap added the complication of sealing weather or fuel from making it's way into the trunk...
So this is what we cam up with.
We made what is basically a can with a bulb seal that fits against the inside of the quarter panel.
The original fuel fill tube was sectioned to account for the length and angle change needed to accommodate the inset depth of the back of the Challenger fuel door assembly.
The flange of the original fuel filler is sandwiched between the "Can" and the fuel door housing.
Any water from washing or weather that comes in through the door or fuel burps or drips when refueling will drain out the bottom of the can nipple and tubing that will be routed out down between the trunk extension and quarter panel. Most likely will feed a line out through the body plug in the bottom of the trunk extension.
The finished fuel door install looks like this.
This is what the backside looked like before sealing it off from potential weather or fuel finding it's way into the trunk through all the gaps in the door assembly.
The fuel door is not weather tight...
The body of the fuel door body is also not weather tight. Spilled fuel or burped will drain out the hole circled in red below. That is a factory drain hole. I did not want it to drain inside the trunk...
The solution isolates the trunk from weather, car washing, or fuel burps or overfill that could have found it's way into the trunk.
The fuel door snaps into the body exactly as with a new Challenger.
The "Can" enclosure uses a bulb seal against the inside of the QP.
The way is is assembled uses the Fuel Door and the "Can" to pull against each other to compress the bulb seal against the inside of the QP.
The can has a length of tubing welded into the very bottom in order to plumb a drain out of the car.
The nipple on top of the fill tube is the factory vent opening, it will have the original vent tube attached to it.
A small section of filler tube removed to correct the length and angle difference between the back of the Challenger door and the original flip-top cap locations. We will be adding a bracket to the lower section of the fill tube to secure it in place by attaching it to the adjacent wheelhouse bracket.
Really happy with the results. Probably way more work that it was worth but it's done... Almost...
Still have to get the fuel tank installed and it doesn't seem to want to fit without being up against the rear shocks... Ugh!
Will get it up on my lift at home to tackle that...
