How to: Remove rubber around the gas flap

[jmackro]

All that said, it is amazing how predictably parts fit on new cars compared to our old ones. Panel alignment windows, gaskets, etc. are all so much more precise now.

Yea, new cars are built with automation and measured by lasers. Older cars - especially the low-production models like the e9 - were just hammered together. Also, reproduction parts seldom fit well (or last very long). The problem is especially acute with rubber seals and gaskets, which tend to be off dimensionally and be harder than the originals.

 

[Jan Gullett]

I wasn’t sure how best to do this so I reviewed this thread. I had done this once before but that was 28 years ago, and my memory was dim. Anyway, this worked for me:

1. Install rubber surround. Tape adjacent paint and door edge to protect from scratches.
2. Lubricate rim of surround with rubber detailer like Armour All.
3. Place light on floor of trunk focused up through bottom surround hole toward center stud.
4. Prepare socket with extra stud nuts taping top nut to socket, add extension and ratchet. Lay in trunk next to light in easy reach.
5. Put door hinge in neutral position halfway between open and closed.
6. Look down through top surround hole at angle to make center stud visible.
7. Slide door at about 15 degree angle from rear to front pushing in on door front edge against lubricated surround edge until you see center hinge hole just above center stud.
8. Close door slightly so stud enters center hole and hold with left hand.
9. Use socket with right hand through upper hole with extension and ratchet to push down on hinge at center stud so threads protrude and start center nut at same time.
10. Use Socket, extension and ratchet with tape to install upper and lower nuts.

Now for trimming rubber to get a decent door close