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  1. #1
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    Default Another Fuel Door Install; 2014 Spyder RTS

    With the help of those of you who had performed this procedure before me, I installed a billet fuel door on my spyder over the last couple of days. And I took lots of pictures! So without further ado;

    This is the fuel door I used.
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    The fuel door taken apart.
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    The seat with tape showing the level line and center point of the gas cap and fuel door. Note the tape showing cap location and fairing start point.
    74E29E9F-EDBF-4FD9-8350-C1DB88107196.jpg

    Another view of center point already punched with soldering iron.
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    Bulls Eye!
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    Hole in seat via the soldering iron with seat vinyl pulled back.
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    Hole marked and ready to cut.
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    I used a 4 1/2” hole saw and turned it by hand to cut the foam. Once the foam was removed, I used the hole saw to cut through the pan (plastic) by running it backwards.
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    What the pan looks like after it’s cut.
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    I pulled the vinyl back into place and marked the cut lines.
    D4DDAFBD-D09E-4AA5-ADB7-3FBEA776AD89.jpg

    I cut the vinyl using a utility knife and cut a piece of leather to line the exposed edge of foam.
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    Then I pulled the tabs formed by cutting the vinyl back and temporarily stapled them on the back of the pan.
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    What the front side of the seat looked like after pulling the vinyl back and stapling.
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    The fuel door clamped into place and ready to punch the holes with the soldering iron.
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    Hardware used; cut the prongs off the t-nuts using a pair of diagonal cutters, punch one hole, insert screw through the front and t-nut through the back. Tighten to hold fuel door in place.
    6F49E5F7-A826-4DE7-993B-5EE85643B71C.jpg

    The t-nut on the high side of the pan will require a bit more trimming in order to ensure clearance when the seat is in the down position.
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    Hardware installed.
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    Hardware trimmed with a dremel tool and cutoff disc.
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    High side t-nut trimmed to fit.
    38ADABCB-74B6-4B31-97A7-09694960BED5.jpg

    Fuel door tightened down, vinyl tabs pulled tight and stapled into place.
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    Back of seat covered with a piece of leather to protect the left side fairing.
    574E2F51-E4E9-440A-A7E5-E0C7D1761636.jpg

    Spray adhesive and staples were used to secure the leather. Vinyl was pulled into place and stapled with stainless steel staples.
    E67A81B9-2D4E-4E7B-9F8C-2E90F6316D02.jpg

    Fuel door installed and closed.
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    Fuel door open…. Note the piece of leather on the latch plate; keeps the door from rattling by tightening the latch and protects my hand from getting cut by the latch plate.
    BCFC350F-DF1A-4897-953A-4222694A03CE.jpg

  2. #2
    Very Active Member BLUEKNIGHT911's Avatar
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    Nice job Thyatt ..... I remember we had a few conversations about how to do this, I'm glad you got it done. ..... But to be honest to anyone else who wants to do this, I didn't do it this way...... When I was doing them as a Vendor my methods allowed me to accomplish it in about 45 minutes.... in a parking lot..... Yours did come out quite nice, and I'm glad ...... Mike
    Last edited by Peter Aawen; 11-11-2022 at 08:59 PM. Reason: Yours ;-)

  3. #3
    Very Active Member Haze's Avatar
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    Looks very nice.
    Great bit of DIY.
    David C
    2017 F3T
    DIY Driving/Fog Lights,
    DIY Garage Door Opener & GPS Mount
    USB port, Battery tender cable
    Rear Pack Rack
    DIY Heated Gear Port
    Cubby Signal Lights & Custom Insignia Light
    Baldwin Ironworks cat delete


  4. #4
    Very Active Member gkamer's Avatar
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    Great job. Looks like a professional install. Cool!
    Greg Kamer
    "If you're not living on the edge, you're taking up too much room"

    USAF, 20 years, retired
    Sheriff's Office, 23 years, retired



    2018 Can Am Spyder RT-Limited

  5. #5
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    Thanks Mike. I took inspiration from our conversations to move from concept to reality. It almost didn’t happen as the door was lost in the mail for a week or so, then the hardware was back ordered. I enjoyed doing this project; it’s more about the challenge and the thought process than anything else. I looked at all the door installs I could find and developed a pros and cons list, then determined the “best practices” from each. I took my time so I could enjoy the experience and bask in the glow of a job well done. Sometimes my OCD gets in the way…. I did learn that taking off the seat is not something I wish to do again anytime soon; I dropped two sockets and a wrench down under the seat frame. Then the seat wouldn’t line back up at hinge points. How an aluminum bushing becomes too long to fit an area it came from is beyond me…

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