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-   -   Custom Aluminum Fuel Bezel - Step by Step build.. (http://www.wranglerforum.com/f322/custom-aluminum-fuel-bezel-step-by-step-build-42275.html)

dave@rokmen 01-04-2010 06:12 PM

Custom Aluminum Fuel Bezel - Step by Step build..
 
Besides our standard inventory of parts we sell accross the country - we also do custom full vehicle builds here in Denver.

With a project currently in the shop, we have to relocate the fuel filler. The space we have to work with is just too small for the stock one to be re-positioned. Normally we'd use a different bezel from a different jeep model. But this is a really nice and complete build. And it deserves something much better than a cheapo bland solution...

We've been thinking about making a fuel bezel for a long time now. Why? because sometimes you just get an idea, and it rolls around in your head for a long time - and eventually you have to make it...

The bezel idea we had is going to be perfect for this project... So it's time to put plan into physical form...

We took a bunch of pictures just to show everyone the process involved, and if your a gearhead - well it goes without saying....

After thinking through the material we had on hand, and the actual finished size we needed - we put the plan in place. The bezel will be made in 2 pieces and TIG welded together at the end to make the final product.

First we start by making the actual outside bezel ring. This is going to be made from some t6 polished aluminum plate. The grade isn't really too important for the function of the part - But it's what we had laying around.

Marking out the piece we need.
http://www.rokmen.com/images/ff1.jpg

Next rough cut the piece out, so it's easier to work with. Even though our rough cut is very close to what we want, we'll still clean it up on the lathe for a perfect dimmension and look.
http://www.rokmen.com/images/ff2.jpg

We start by making a big hole in the center of the part.
http://www.rokmen.com/images/ff3.jpg

Then we make the big hole even bigger, until we get the inside dimmension we are looking for. We also work the outside dimmension as well to make it perfectly concentric.
http://www.rokmen.com/images/ff4.jpg

Then it's over to the mill where we put all the bolt holes in and countersinks for the flush hardware.
http://www.rokmen.com/images/ff5.jpg

And here is what the final part looks like - final check of measurements and so on - and we are off to the second piece.
http://www.rokmen.com/images/ff6.jpg

The second piece is what is going to make up the actual filler neck, and will be made from this piece of solid round t6 aluminum. Again the grade really didn't matter much.
http://www.rokmen.com/images/ff7.jpg

Then back to the lathe where we start with a big hole in the center again.
http://www.rokmen.com/images/ff8.jpg

Then we make that hole even bigger too..
http://www.rokmen.com/images/ff9.jpg

Then it get's flipped around for some work on the backside and final dimmensioning.
http://www.rokmen.com/images/ff10.jpg

dave@rokmen 01-04-2010 06:13 PM

Back over to the mill for the filler neck holes.
http://www.rokmen.com/images/ff11.jpg

And here it is, final check and it's ready to go...
http://www.rokmen.com/images/ff12.jpg

This is just a different angle so you can see it matches what we were looking for.
http://www.rokmen.com/images/ff13.jpg

This picture is going to be familiar - It's the two pieces being aligned together and getting ready for TIG welding.
http://www.rokmen.com/images/ff14.jpg

And here is a view of the pieces after they have Been TIG welded.
http://www.rokmen.com/images/ff15.jpg

And this is the completed custom bezel after being cleaned up - with the countersunk hardware and gas cap in place.
http://www.rokmen.com/images/ff17.jpg

http://www.rokmen.com/images/ff16.jpg

Pretty darn cool.......

The only thing left is to mount it on the project vehicle - from there the owner can decide how he'd like to finish the part, polished, brushed, annodized etc.... But that will not be decided for another month when the project is closer to completion and ready for paint etc..


rokmen

89PBR96 01-04-2010 06:17 PM

AH the pictures are here lol looks pretty sweet man

MCDavis 01-04-2010 06:57 PM

Black anodized would look good on my LJ.... ;)

Ray - San Jose 01-04-2010 08:59 PM

Very nice! :D

HyperBuzzin 01-04-2010 10:09 PM

Looks good!
Ya got any openings for a layed off Machinist? LOL

jeep41 01-04-2010 10:12 PM

Thats awesome looking

HyperBuzzin 01-05-2010 08:28 AM

Does it have any drain hole for water or accidental gas spillage?

jgano23 01-05-2010 08:31 AM

sweet. can you post pics of the rig when it is complete?

MR.CLIFFORD 01-14-2010 02:58 PM

Dang. I was gonna guess it was a spare tire mount for the freak since straps are for suckas!


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