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Old 11-17-2003, 12:21 AM   #1
jorgensensc
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INSTALL: Tennman's Sidemarker Fuel Fill on a Stepside

Finally got around to showing the install! I hope this helps everyone. There are alot of pics, so it might take awhile to load them all.

Here is what I used:

1- 1997 S10 fuel filler door with neck
1- 1 1/2 fuel filler hose (see blazer tank install for part number)
3 ft of 5/8" hose
4- 1/4" machine threaded bolts 1 1/4" long
4- nylon lock nuts for above bolts
2- 1/2" spacers for above bolts
1- permacap gas cap (optional)
1- large can of patience!!!

Here are the parts I got from the local wrecking yard:
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1972 C20 Suburban- Big Blue Betty
'56 Chevy Bel Air Sedan- Frame up Restoration

-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 12:22 AM   #2
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more pics of junkyard parts
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1972 C20 Suburban- Big Blue Betty
'56 Chevy Bel Air Sedan- Frame up Restoration

-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 12:24 AM   #3
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sidemarker light
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1972 C20 Suburban- Big Blue Betty
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R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 12:26 AM   #4
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backside of light,
You will need to grind smooth the ridges around the bolt holes on this side. Also grind off the white ridges on the ends near the bolt holes.
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R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 12:47 AM   #5
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Here is the top of the fuel filler neck. You will need to weld on an exhaust reducer fitting that goes from 2" ID to 1 1/2"OD on the bottom. I cut the filler length to just below the vent hole fitting.
I could only find a 2" ID to 1 1/2" ID so I had the fuel filler hose stretched with an exhaust pipe stretcher.
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Old 11-17-2003, 12:50 AM   #6
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Here is a pic of the sidemarker hole where the lense goes. My fender had this metal backing on it.
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Old 11-17-2003, 12:51 AM   #7
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another pic without the light.
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Old 11-17-2003, 12:52 AM   #8
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Here is the backside of the fender.
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Old 11-17-2003, 12:54 AM   #9
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You have to cut out the basket.
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Old 11-17-2003, 01:05 AM   #10
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All that is really involved is cutting the fuel door to match the width and height of the sidemarker lense. Measure between the white ridges up and down (approx. 2 1/2"), but measure to just outside the bolt holes ( about 1/8" past on both ends turns out just past 3 1/2" length). My fuel door faceplate (big round part) seperated from my hinge piece, so I had it welded together again.
You can see the weld spot on the side in this pic.
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R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 01:20 AM   #11
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Drill the holes for the lense and cut out a notch for the light. I used the original screws and just cut them off on the back side.
Now the bolt flanges on the back part of the hinge base will need to be cut off. Sorry no pics, but you will know which ones they are. They are little tabs with nuts welded on the backside. These were used to bolt the hinge on the S10. Feel free to try and make these work for you, but I couldn't, so I cut them even.
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Old 11-17-2003, 01:26 AM   #12
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Here comes the hard part. Drill 2 holes in the lip of the hole on the fender (where the light goes) These will be used to mount the hinges in place. While your at it drill the holes on the opposite side also. These holes will be used to hold on the plastic fuel tray.
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R.I.P. EAST SIDE LOW LIFE

Last edited by jorgensensc; 07-06-2004 at 10:39 PM.
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Old 11-17-2003, 01:33 AM   #13
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Next hold the assembly (hinge assembly with lense attached) up in the hole. You need to open and close the assembly while holding it in place to get the alignment right. The best way is to hold the hinge underneath while the lense is in the right spot. Have your helper open the door slowly and then mark the through the holes you drilled in the lip to the hinge. TRIPLE CHECK YOUR MARKINGS!!!!!!! I cannot stress that enough. Then pull the assembly and drill the holes. Make sure they line up appropriately after you drill them. Next bolt it in. I had to add some washers as spacers between the fender and the hinge to help bring the back half of the hinge more flush.
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Old 11-17-2003, 01:34 AM   #14
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Here it is installed:
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-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

Last edited by jorgensensc; 07-06-2004 at 10:46 PM.
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Old 11-17-2003, 01:35 AM   #15
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Another (again)
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R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 01:45 AM   #16
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Next bolt on the fuel tray to the filler neck.
I actually bolted on mine upside down, with the hole in the filler neck towards the top. This makes it easier to fill with gas. I tried it the normal way, but there is not much room, so this was the fix. It doesn't seem to affect anything. Hook up the hoses (the filler hose and the vent hose). Next hold the assembly (filler neck with tray) up to the hole. Find where you will need to trim the tray, then pull the tray off and trim what you need to trim. You will need to do some trial and error here. What I did was leave it loose, take it to the gas station, Insert the gas nozzle, then mark the location of the tray. I also marked the holes I drilled earlier on the fuel tray.
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1972 C20 Suburban- Big Blue Betty
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-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

Last edited by jorgensensc; 07-06-2004 at 10:44 PM.
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Old 11-17-2003, 01:51 AM   #17
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Heres another of the filler neck installed. The Blazer tank inlet and the filler neck match almost perfect. When I installed the fuel tray I added spacers between the tray and fender. Once again to give a little more room when adding fuel.
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1972 C20 Suburban- Big Blue Betty
'56 Chevy Bel Air Sedan- Frame up Restoration

-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 01:56 AM   #18
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Drill the holes in the tray for the bolts (once again TRIPLE CHECK before you drill. There isn't alot of room to play with on the tray. You might need to do a little 'tweaking' and bending to get everything to line up properly.
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-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 02:03 AM   #19
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Make sure when you open the door, the lense doesn't hit the side of te bed. I remedied this by bending the hinge a little, so it didn't open to a full 90 degrees.
Here is the reason for the Permacap:
I installed everything and put the regular gas cap on and put the light in. The light harness hit the gas cap. So I got the permacap because it has a lower profile. Now the light clears just fine. I still have to remove the cap to fill the tank (California gas nozzles have huge adapters on them and they won't fit in the light hole well). But I really don't mind much.
Here are some pics of the final product:
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1972 C20 Suburban- Big Blue Betty
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-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

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Old 11-17-2003, 02:04 AM   #20
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more
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-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

Last edited by jorgensensc; 07-06-2004 at 10:53 PM.
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Old 11-17-2003, 02:12 AM   #21
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Since they seem to go together, here is the link to the blazer tank install:
BLazer Tank Install

Also I put a new light harness in and zip tied it discreetly to the hinge after I wrapped it in electrical tape.
Hope you enjoyed this post!!!
It's really not that hard, just tedious and it takes a little tweaking.
If you have any questions, please feel free to ask!
Shawn
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-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE

Last edited by Palf70Step; 09-24-2006 at 03:23 PM.
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Old 11-17-2003, 02:40 PM   #22
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thanks for the detailed instructions... my question relates to the picture of the filler hose that routes under the frame to get to the tank... trying to understand how the fuel runs uphill to get into the tank...??? I guess the new style filler allows this to be possible...???
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Old 11-17-2003, 09:45 PM   #23
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Thanks for all of the support guys!!!
I hope no one thinks this is my idea!!! I just modified Tennman's install for a stepside.
Bigvinnie,
It is only a slight uphill slant, and the force of the gas going through the nozzle pushes it through just fine. I have yet to have it back up on me.
Thanks again for the encouragement!!!
Shawn
P.S. I don't know if Josh decides about what goes to the FAQ section, but I think both the blazer tank install and this install would be good candidates.
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1972 C20 Suburban- Big Blue Betty
'56 Chevy Bel Air Sedan- Frame up Restoration

-What would you attempt to achieve if you knew you could not fail?-

-I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door-

R.I.P. EAST SIDE LOW LIFE
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Old 11-18-2003, 06:43 PM   #24
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Awsome work bro, any idea how I would adapt this to work on a fleetside?
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Old 06-12-2005, 09:01 PM   #25
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there is no fleetside install. here's one though
http://www.classicheartbeat.com/mark...t_gas_door.htm
it's not as easy as a stepside because you have to cut a hole in the inner bedside then weld a patch over it, but the results are similar.
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