60-66 Tail Light Gas Filler

[Asshat]

Originally Posted by 65ChevyUtah

So I received the kit yesterday but the instructions are incomplete. I emailed c10crewcab and he replied back he is modifying the instructions and will email them over to tomorrow.

After looking at the kit it’s going to require a pretty good amount of time to remove the inner part of the stake pocket. I am hoping it won’t jeopardize the structural integrity of the bed by cutting it out. It does say on the website this isn’t a 1 hour job and requires some fabricating skills but this looks pretty intense. I am not a rookie fabricator but it’s gonna be tough cutting in such tight spaces. I am hoping the new instructions tell me what tools he used to cut it out. I’ll post an update with the instructions.

I am also worried a little about fuel flow since the fuel
Hose will be pretty much flat for about 18” before dropping into the tank. I wish they would have shown the whole install in their promo videos and in the picture.

If anyone is considering getting this kit you might hold off for a bit until a few of us have actually got it installed successfully and the instructions are updated.

I was wondering how to get in there and get that section cut out. Very little room.
Anyone have any ideas?

[MT65]

Your best tool for trimming behind the light is a small air reciprocal saw, easy to manage and can cut small radius.
Don’t know what they are installing, however I did not cut anything out the stake pocket…hopefully your project goes well…

[65ChevyUtah]

Originally Posted by MT65

Your best tool for trimming behind the light is a small air reciprocal saw, easy to manage and can cut small radius.
Don’t know what they are installing, however I did not cut anything out the stake pocket…hopefully your project goes well…

Thanks.
Good to know. So how did you fit the fuel hose ? The kit requires the inner stake pocket to be removed to fit the fuel hose and the filler neck.

[61hawk]

I didn't do a taillight gas filler install but I did do a stake pocket filler install. Yes it is a pain to get things cut out inside the stake pocket. I can't exactly remember what we did, this has been a multi-decade restoration, but it was probably a combination of hole saw and sawzall with a long blade. I also ran into the problem with fuel fill hose and decided to go with a mandrel bent stainless tube that I bought off the jungle website. I connected the filler cap to the the tube with a piece of fuel fill hose and had to get a neighbor to help me get everything in place because it had to be installed from the bottom. Wasn't fun. My tank is under the bed and there is only a slight drop from the stainless tube to the tank. Still trying to figure out how to do venting, hopefully the vent ports in the tank along with rubber tubing will be enough to keep me from having to take a half hour to fill.

[MT65]

Originally Posted by 65ChevyUtah

Thanks.
Good to know. So how did you fit the fuel hose ? The kit requires the inner stake pocket to be removed to fit the fuel hose and the filler neck.

If you look at the filler in my picture, you will see it is outside the stake pocket and inside the fender…had to do some re-directing of the tube on the filler, the GTO filler was all stainless so no worries about rust…I used a 90 degree bend fuel hose to match size with the filler, then a straight piece across to close to the frame, then a short piece of filler hose to attach to the tank…the is a vent off the tank 3/8, that is up to the same elevation as the filler neck behind the light, it is capped with a inline fuel filter so it can breathe yet nothing can get in animal wise. If you notice, the filler has a spring loaded flapper that the gas nozzle goes through, with that and the fuel cell foam piece there is no worries of sloshing out, and no more odorus than the ones from the factory….

[Asshat]

Originally Posted by MT65

If you look at the filler in my picture, you will see it is outside the stake pocket and inside the fender…had to do some re-directing of the tube on the filler, the GTO filler was all stainless so no worries about rust…I used a 90 degree bend fuel hose to match size with the filler, then a straight piece across to close to the frame, then a short piece of filler hose to attach to the tank…the is a vent off the tank 3/8, that is up to the same elevation as the filler neck behind the light, it is capped with a inline fuel filter so it can breathe yet nothing can get in animal wise. If you notice, the filler has a spring loaded flapper that the gas nozzle goes through, with that and the fuel cell foam piece there is no worries of sloshing out, and no more odorus than the ones from the factory….

I thought the filler neck in your setup looked like it was off to the side. How did you secure it the the bed?

I’m wondering how I will get a fill nozzle in there. The ones in California are pretty big.

[MT65]

I made a small bracket, welded it to the filler, then bolted it with 1/4-20 machine screw to the pad that originally mounted the light….all the fasteners you see screw into thread-serts, making it a one person operation…
You will most likely have to hold the fuel nozzle boot back, or I hear Utah is nice….

[65ChevyUtah]

I received the updated instructions yesterday and got started. It’s one of those projects you just have to find your own way of doing it. I used a combination of a regular cut off wheel, air body saw, dremel style cutting disc and drill bits. I still have the lower cutting part to do.

Here are some photos :
https://ibb.co/bXJT0pv
https://ibb.co/zJMVKJv
https://ibb.co/gJt4R9x
https://ibb.co/vdMj8zC
https://ibb.co/XWFY0nr
https://ibb.co/rM0tQJ4

[The Rocknrod]

Very good, looks like your getting it done.

[MT65]

Looks great…

[Asshat]

Got mine all butchered-up; mounted a filler neck in there, but I think I’m going to re-do it.
Still not sure how I’m going to hinge-it.

I was thinking about skipping the hinge and just make it removable, mounted with magnets and a cable tether, so I don’t lose it. It doesn’t really need to have a hinge; you could just pull it off and let it hang while you’re filling up.

[ls60apache]

this was something i was playing with years ago....i used a i think a hinge from 98 dodge stratus with some mods...works ok could use some refinements[ATTACH][ATTACH][ATTACH][/ATTACH][/ATTACH][/ATTACH]

[Asshat]

Originally Posted by ls60apache

this was something i was playing with years ago....i used a i think a hinge from 98 dodge stratus with some mods...works ok could use some refinements[ATTACH][ATTACH][ATTACH]Attachment 2146045[/ATTACH][/ATTACH][/ATTACH]

I like it!

[MT65]

This is what I had in mind when I did mine, however my lack of mobility at the time, made me do what I did …..yours looks fine….

[61hawk]

I'm liking all three, the last one with the upswinging hinge is my favorite, throw in the capless filler and have it all hid in the stake pocket and you'd have the best of all worlds. Too bad I'm past the paint phase and not willing to start over.

[65ChevyUtah]

Originally Posted by 61hawk

I'm liking all three, the last one with the upswinging hinge is my favorite, throw in the capless filler and have it all hid in the stake pocket and you'd have the best of all worlds. Too bad I'm past the paint phase and not willing to start over.

I hear ya on the paint. I just painted mine a few weeks ago. I am trying to be really careful and not do any damage that the tail light wont cover. Ive had to cut slowly so the metal doesn't get too hot and bubble the paint.

[Asshat]

Any recommendations for an inexpensive charcoal filter for the vent tubes?

Would this work?
Standard Ignition LDP74 Fuel Vapor Canister Filter https://www.amazon.com/dp/B07W5R7JVB...ing=UTF8&psc=1

[65ChevyUtah]

I have no experience with the vent but I like the ideal of a charcoal canister. That looks like it would work.

Originally Posted by Asshat

Any recommendations for an inexpensive charcoal filter for the vent tubes?

Would this work?
Standard Ignition LDP74 Fuel Vapor Canister Filter https://www.amazon.com/dp/B07W5R7JVB...ing=UTF8&psc=1

[Asshat]

I’m pretty much finished. Tank is installed and running.
Might have to work on the lead-in for the thumb screw.

https://youtube.com/shorts/84Z39JgKfBE?feature=share

[61hawk]

Originally Posted by Asshat

I’m pretty much finished. Tank is installed and running.
Might have to work on the lead-in for the thumb screw.

https://youtube.com/shorts/84Z39JgKfBE?feature=share

I agree with it not having to be hinged, I wonder if there's a quarter-turn, thumb screw that could be used.

Next you can work on an in cab release system.

[Asshat]

Originally Posted by 61hawk

I agree with it not having to be hinged, I wonder if there's a quarter-turn, thumb screw that could be used.

Next you can work on an in cab release system.

Yes - that would be cool. Got a few other things on my list:

- [ ] Radio - with new electronics
- [ ] Seat belts
- [ ] Tires - 215/85-16
- [ ] Ebrake IPSCO
- [ ] 4bbl Intake manifold or a V8
- [ ] Mirrors

Not necessarily in that order.

[Justin71105]

Older post but I really like the brake light fuel filler.

Saw a fb video of one attatched to a 99-06 fuel door assembly like the dodge stratus one above. It flipped down and would work great with one of the fill theough caps you don't have to remove.

Looked really good, may try this route out.

Trim the inside out then weld a plat at 45° inside and drill a hole for a filler neck to go.

Then run pipe like shown, fuel door assembly looks to shut solidly enough, maybe use a strong magnet to hold it from popping open if it doesnt.

[Lokin4AReason]

Really liking the idea(s) being tossed around in the thread . . .

[1966c10shrtbd]

[ChrisDollins]

Originally Posted by 1966c10shrtbd

Attachment 2224811

Man that is so cool! Me and a friend were talking about fill options today and just could not come up with anything. But that is about perfect. Do you have any other pictures or tips on doing it?

Chris