My RT Fuel/Gas Door DIY

[ggivens]

Items:

Bully Gas Door with a 4 1/2" inside hole diameter Part#: GD-301
BRP Comfort Seat with Backrest (a little different from the standard seat)

Tools:
Lenox 4 1/2" hole saw with arbor
Power drill for 3/8 drill bit size
Large towel to cover bike near the seat
Pair of work gloves
7/16 wrench
#20 Star Driver TX20
Flathead screwdriver
Phillips screwdriver
Pliers
Scissors
Files: 1 flat and 1 small round
Thin line red or white removable ink marker or pen
Exacto knife or box cutter
3 Machine flat head Philips screws with nuts: 1/4-20 x 1in
3 Machine flat head Philips screws with nuts: 1/4-20 x 3/4in
3 Machine flat head Philips screws with nuts: 1/4-20 x 1 1/2in
3 Machine flat head Philips screws with nuts: 1/4-20 x 2 1/2in
2 Machine flat head Philips screws with nuts: 1/4-20 x 3 in
Note: These screws might be needed because the 4 screws on the fuel door are short. Just have them
handy in case you need to use different size screws to mount the door

Installation:
Step 1: Cover working area with towel (there will be lots of shavings)
Step 2: Optional: Pull the outside cover back enough for the fuel door to fit
Step 3: Position the fuel door on the seat over the gas tank cover with the seat down
Step 4: Make sure the door hinge is horizontal and to the left
Step 5: Outline the outer edges of the fuel door
Step 6: Outline the inside diameter of the fuel door
Step 7: Mark off the center of the inside fuel door hole
Step 8: Drill the starter hole with a 3/16" bit in the center of the inside hole from the outside of the seat
Step 9: With the seat up, on the inside of the seat start drilling with the hole saw using the starter hole as a guide.
Step 10: Drill into the plastic seat very lightly until the hole saw starts to make a deep cut in the plastic
Step 11: Cut through the plastic and the layers of padding; determine if you want to continue through the outer cover or cut that out using scissors or exactor knife (file the edges of the plastic seat if needed).
Step 12: Line of the fuel door is horizontal with the hinge to the left and mark off the mounting hole
Step: 13: Drill the mounting holes using a 3/8 drill bit
Step 14: Mount the fuel door with the bolts that fit each hole's length