Broken Gas Door Hinge Fix

[MrAl]

Maybe Volvo has changed their supplier? I never used a hammer. These should be a push fit. I used a large punch (big enough to more than cover the head but not too big so I could see what I was doing). Some silicon oil on the plastic pins may also help.

Return it an ask for a non-defective part.

Neil.

Hi,

Oh i didnt know you could just push them in and the reason i used a hammer is because that is what the file i downloaded from IPD told me to do.
Yes some oil could have helped and i was going to test the pins to see how smoothly they went in before i went out there but forgot to do that. If i had noticed they went in easy i could have avoided the hammer issue.

But you know what they say: live and learn, then forget and live and learn again, then forget and...

I am still thinking this over though. I should reach a decision on how i want to handle this by the end of today.

[scot850]

Nothing like pondering an issue into procrastination I say!

I am terrible for overthinking an issue (or Engineering it to death). You are doing the right thing and walking away and often for me that brings a simple solution. Good Luck!

Neil.

[MrAl]

Nothing like pondering an issue into procrastination I say!

I am terrible for overthinking an issue (or Engineering it to death). You are doing the right thing and walking away and often for me that brings a simple solution. Good Luck!

Neil.

EDIT:
The M4 bolts fit through the new hinge but not the hold hinge plastic. Not too big of a deal but thought i would mention it.

Hi,

Wow are you right.

Here is the temporary $10 USD solution just put it on an hour ago. Locking gas cap. See photo.

The long range plan can be seen in the photo also, the second hole up from the bottom. It's a rivet nut.
It's an M3 size and It's a tiny tiny bit loose before installation so i may go with M4 which happens to be the size of the hole the pin fits through too. The M4 would require the sheet metal hole to be enlarged just very slightly probably 1/32 of an inch. M3 would be nicer though maybe, it's a little lighter duty and allows a little wiggle room for alignment, and no drilling.
So the next decision is to go with M3 or M4 but after that it's go time. Tomorrow if it is nice enough out there, today cold as heck.
I think i'll go with M3 first and see how that works, if it doesnt work out that well i will do the other holes with M4 after enlarging the sheet metal holes a tiny bit.

So just for reference, M3 will most likely work and easily fit through the holes already in the plastic hinge.
M4 will be stronger but require drilling the sheet metal body of the car out just a little, but they do fit nicely through the plastic hinge where the pins normally push though. An advantage is strength, and also nothing to take apart.

Hopefully tomorrow is a nicer day.

Thanks Neil.

P.S.
Hey, 3d ABS printer make our own parts

[MoVolvos]

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Do not drill! When I worked at Acura mid 90's as an entry level tech part of my job was to install accessories. Phones, entire AC (imagine that) and spoilers etc... The rear trunk was difficult to drill and the sheet metal was always rough looking. Getting rid of the burrs and roughness was always difficult. Acura didn't provide bits so that was not helpful. We had to use primer and touch up paint before installation.

The sheet metal at the fuel tank area is too thin for fractional enlargement. Will most likely flex, be uneven and worse case rough making the hinge seat unevenly. If you ever need to replace it, drilling the rivet on a soft area will be problematic.

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[MrAl]

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Do not drill! When I worked at Acura mid 90's as an entry level tech part of my job was to install accessories. Phones, entire AC (imagine that) and spoilers etc... The rear trunk was difficult to drill and the sheet metal was always rough looking. Getting rid of the burrs and roughness was always difficult. Acura didn't provide bits so that was not helpful. We had to use primer and touch up paint before installation.

The sheet metal at the fuel tank area is too thin for fractional enlargement. Will most likely flex, be uneven and worse case rough making the hinge seat unevenly. If you ever need to replace it, drilling the rivet on a soft area will be problematic.

*

Hi,

Not sure what you mean by thin metal. i guess you figure the metal will pull out of shape with the bit flutes?
i could use a Dremel i guess but that could cause sparks.

Replace what the rivet?

[MrAl]

Hi,

Finally fixed. I used M3 rivet nuts and M3 screws. Pretty solid.
I'd post a picture but not much to see really, it looks like it is normal except for the screw heads.

[MoVolvos]

*
Do not drill! When I worked at Acura mid 90's as an entry level tech part of my job was to install accessories. Phones, entire AC (imagine that) and spoilers etc... The rear trunk was difficult to drill and the sheet metal was always rough looking. Getting rid of the burrs and roughness was always difficult. Acura didn't provide bits so that was not helpful. We had to use primer and touch up paint before installation.

The sheet metal at the fuel tank area is too thin for fractional enlargement. Will most likely flex, be uneven and worse case rough making the hinge seat unevenly. If you ever need to replace it, drilling the rivet on a soft area will be problematic.

*

Hi,

Not sure what you mean by thin metal. i guess you figure the metal will pull out of shape with the bit flutes?
i could use a Dremel i guess but that could cause sparks.

Replace what the rivet?

*

Yes, sometimes the rivet will just spin while drilling and the metal can get a bit out of shape while enlarging the hole.

*

[MrAl]

Hi,

Yes i ran into that before i the past too. It can be a pain. Only way i would think would be to use a Dremel and stone wheel, carefully. I'd hate to have to do that around the gas tank cap though. Maybe cover it with a very wet rag first.