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rear gas tank door area fixes

Discussion in 'Body Work & Detailing' started by katt68, October 2, 2002.

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    1. katt68

      katt68 Member

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      City, State:
      halifax, nova scotia,canada
      Year, Model & Trim Level:
      1992 xl
      i have a 92 xl and i have been told it is common for the explorers to rust out in this area. if it is so common what are the options to fix the area instead of replacing the whole panel? what about fiberglass? what do you folks reccomend? please give me any suggestions. thanks from the katt.
       
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    3. 88vert

      88vert Explorer Addict

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      94 unlimited
      My cousin is doing mine as we speak and he took off the panels from the inside and is attacking the rust from both sides mine was just starting to pop through:(
       
    4. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      Replacing the whole panel will be the most costly.
      Patching would be the ticket.
      I don't know if you can get just the fuel pocket , I'll have to check tomorrow.
       
    5. ajevenson

      ajevenson Active Member

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      Before you cut the section out or bondo it. Make sure you run your fingers in the gap between the body and the fuel cap (inside the fender). You'll find a lot a wet sand/gravel/mud. The only way to keep the newly replaced panel or bondo'd area from rusting out again is to close that area of the wheel well off so that moisture doesnt keep going in there every time you splash through a puddle. I used bulk rubber matting designed for entranceways to close the area off.
       
    6. 94XMike

      94XMike New Member

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      THE GAs?

      What about being so close to the gas and cutting the rust out? Isn't that kinda dangerous... I wanna fix mine, but I also don't wanna blow myself up in the process! What did you guys end up doing?
      THX,
      Mike :chug:
       
    7. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      Leave the gas cap ON.
      Mind the direction of your sparks.
      DO NOT USE A TORCH.
      If you are doing the filler area remove the filler neck.
      ( a few hose clamps and some screws )
      Duct tape over the tank opening and put a fan under there to keep the fumes
      moving.
      Remember gas fumes are FAR, FAR more dangerous than gas itself.
       
    8. have2goski

      have2goski Active Member

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      i fixed that on my '91

      you are definately gonna want to pull the interior panel and the rear washer tank and have a look in behind there. The best thing to do would be cut out the rust and strip back the paint around it so you know you are into good solid metal. Weld in a patch that you took your time to fit first. I used expandable foam to back fill the area where road gunk gets kicked up and trapped in there. It is a result of the gas filler channel being cut into that wheel well area. Use body filler on the front side and sand it out for paint. Use your hand and not you eyes to tell you when you have sanded it smooth. I can't stress how much easier your life will be if you really take your time to shape your patch piece as close to the original contours as possible. When you think you have got something pretty good, see if you can make it just a little bit better.

      once you get to welding have a buddy on standby with a shot of shop air or even a spray bottle to put out any unexpected flare ups. If you can get the filler neck out of the way and remove the plastic "cup" thats behind the gas door, you won't have as many problems melting/burning that plastic and it might make it easy to work with your patch piece.

      and it won't be long before we start talking "Bondo" and MONMIX tells you Bondo is a brand, and what you really want to use is a filler called Evercoat. I'll back him up in saying this stuff really is better than the bondo brand. I have used both and although i am only a hobbiest, the stuff really seems to have less air in it or something. really helps get you a nice smooth repair. Bondo will work fine and is tested and true in the eyes of the hobbiest, but if you can get that other stuff.......its the way to go
       
    9. CdnCory

      CdnCory Active Member

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      Year, Model & Trim Level:
      '93 2-door
      Cut the whole section out, weld a new one in. (then drive around with the 1/4 panel primered until you have enough money to paint it)
      [​IMG]
      You can check out my page here for some before pics
       
    10. Minivek

      Minivek Active Member

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      Thread ressurected I know :D But where did you get that new quarter panel??? Nobody seems to sell them anymore. I've got a 94 sport.

      Thanks
       
    11. vroomzoomboom

      vroomzoomboom Elite Canuck STOCK SUCKS! Elite Explorer

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      that and take a cloth, soak it in water, and wrap it around the filler neck with the gas cap on
       
    12. quicklook2

      quicklook2 Active Member

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      national parts depot has the patches in thier catalog.
       
    13. WoodsBuggy3

      WoodsBuggy3 New Member

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      City, State:
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      Year, Model & Trim Level:
      92 4wd Sport
      Anyone had any luck finding that rear quarter for a 2dr?
      Called National Parts Depot, they said they only carry parts for the F-Series and Bronco's? :banghead:
       

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