[scvscions]

a little video of the whole thing:
custom 2008 scion gas door creation on Vimeo

Things that you will need:
Painters tape (not required but highly recommended)
Drill
Misc Drillbits
Chisel (not reqiured)
Dremel
Acrylic (Home Depot, Lowes etc.. Hobby grade)
4 small screws (I choose black anodized screws)
Black Marker
screwdriver
Use some painters tape to tape around the area that your working with so that you don't scratch up your paint.
Start by removing the the teether a from the gas cap that's hooked to the frame of the gas door and the 2 rivets on the body either by drilling out the centers or chiseling the heads off. Be cautious of sparks (I didn't create any but you never know)

Once they're removed it will look like this

here's the back of the door with the frame exposed

Cut at the red points. The door skin is spot welded into place

I used a small dremel for this

Here's a few shots of the cuts


Here's a pic of the frame and the door skin

You can use the door skin for a templete and use the dremel to cut out the acrylic gas door

Then place the door skin with the acrylic on top of it in the oven at 250 degrees F for 20 minutes so that the acrylic takes the shape of the original door

Use a black marker and mark 4 spots as shown in the pic

lay the acrylic piece over the frame and lightly mark the spots that need to be drilled in the acrylic

here the frame drilled out

I wanted a coat of low gloss black so I just used what I had in the garage

Then I added the screws into the acrylic

I used metal drywall ancors to secure the gas door assembly to the car. There's alot of adjustment in the two screws so it can be centered

You can smoke the acrylic from the inside to get the look you want.

[SAKURA]

props jason!

are you gonna use them color "dye" for plastic that we would use in high school?....... or just use colored plexi.

btw, do i see a chrome one?...........gen1?

btw, door molding around the edges?...

great job jason.

[gothbox]

some good work there,
do you think that some of the extra "crap" of the door frame can be removed to make the "window" larger? I mean all you really need is the back part that attaches to the car and the front that keeps it closed right?

Or am I just COMPLETELY out of line here.

[PCH]

Cool mod for sure
Is it 1/8th thick sheet?

[scvscions]

Originally Posted by SAKURA

props jason!

are you gonna use them color "dye" for plastic that we would use in high school?....... or just use colored plexi.

btw, do i see a chrome one?...........gen1?

btw, door molding around the edges?...

great job jason.

I already have one done for the fisrt gens that I made for my box but I sold the box before I could do the next part of the testing. I'm going to get a gen 1 at the house for the day and finish that project.
i can do it in chrome acrylic, mine I'm going to candy and see how that looks

Originally Posted by gothbox

some good work there,
do you think that some of the extra "crap" of the door frame can be removed to make the "window" larger? I mean all you really need is the back part that attaches to the car and the front that keeps it closed right?

Or am I just COMPLETELY out of line here.

No you'd just have to be careful not to ruin the structure or totally re-do the hinges and latch with something less noticable.

Originally Posted by PCH

Cool mod for sure
Is it 1/8th thick sheet?

.093 clear

[scvscions]

Update Pics:

[hotweelz4me]

This is always an interesting mod, nice to see it applied to a 2nd gen. I have to agree with Goth about removing some of the material on the frame. Pair this with the TRD filler cap and it will look pretty cool

[Padanky]

Looks a 100 times better candied. Some of the gaps look a little big.

You could maybe add a spring to hold itself closed, ditch all the framing but the hinge, and cut a little half circle off the edge so you could pull it open.

[shortbus_8]

Choice "j" Dig It