Diesel Bombers - 3rd Gen Tech: Custom Fuel door

I wanted an aftermarket Locking Fuel door, but the only ones available were chrome.

My truck colors are primarily Silver and Black, and I wanted to stick with that.

I decided to blow $50.00 bucks on the chrome one and modify it to match my color scheme.

I don't have any step by step pictures, as the modification was performed out of town at my Dad's house, away from my digital camera.
I did take pics of the finished product, though, and figured I'd just detail the steps necessary to do it, in case someone else wanted to do the same thing, even if they didn't want to use the same color.

First, the finished pics. They are blurry because it's dark out and the shutter wanted to stay open a while.. Sorry. Maybe I'll retake them later in better light.

http://i25.tinypic.com/20z8ozb.jpg

http://i31.tinypic.com/sq5o21.jpg

The first thing to do is disassemble the new Fuel door and prep for paint. I removed the 6 stainless Allen screws and the lock.

Next, using some 200 grit wet or dry sand paper I sanded the chrome Fuel door in a combination of circular and straight motions. The most important part here is not to just straight sand it, you will want to vary your sanding pattern, for best results.

The purpose of sanding it is increased paint adhesion, Paint will not stick to any unsanded areas, so be sure you pay attention to sanding the edges, scuffing the entire surface. You wont want the paint peeling off later due to lack of preparation.
I sanded it both inside and out, as I intended to paint the entire fuel door so no chrome would show. I spent about 30 minutes sanding the entire fuel door.

I began painting by spraying the edges first. Then I painted the back of the Fuel door. I applied 3 coats, making sure to overlap, and keeping the working area wet, to avoid frosting it with overspray.

While waiting for the back side to dry, I removed the stock fuel door (2 Torx screws hold it on). You also have to remove the 2 rubber snubbers on the right side of the door. The door mounts on the existing stock mounting holes. I planned on using the rubber snubber holes for an additional mounting spot (4 stainless allen screws hold my door on).

When the back was dry enough, i flipped it over and painted the outside of the door. Like the back side, I used 3 coats. After allowing plenty of time for it to dry, I carefully re assembled the door, beginning with the upper and lower allen screws and then the lock.

The 2 allen screws on the left mount the door to your truck. the 2 scews on the right are for the new door snubbers.
I added a washer and used them as mounting points also.

It would be easy to paint the fuel door with any choice of color to match your truck's color scheme, or even paint it the same color of your truck to give it a "Custom Stock" look.