INSTALL: Tennman's Sidemarker Fuel Fill on a Stepside - The 1947 - Present Chevrolet & GMC Truck Message Board Network

kaycee · 11-17-2003, 06:13 PM

Thank you very much for the installation pic's, very much appreciated.I found out that my light box has been modified a little,so that is where I was confused.Now I can weld some tabs on the front to mount the hinge to.All I had was a little tab on both ends where the light screws on now I can start working on it again.GOOD JOB

**Yukon Jack** · 11-17-2003, 01:13 PM

Nice detail on this. This needs to make it into the FAQ section.

toms68cst · 11-19-2003, 01:31 AM

I hate to raise this question but how safe is it to have an operating light right on your fuel filler door? If I'm looking at the pictures right the light looks operational.

It's not just what might happen in a minor fender-bender accident it's what might happen if the filler nozzel should damage the wiring.

I'd be inclined to make it just a reflector. It seems like the potential for spark and fumes to come together exist.

Longhorn Al · 11-17-2003, 05:00 AM

Great job and nice truck. Oh, and nice hat!

RON WOODGEARD · 11-17-2003, 09:37 AM

Excellent Documentation!!!

I have posted before, I am filling mine through a garden hose right now, ( not driving it on the street yet still ) I want to do just what you did, thanks for saving me a lot of time and aggravation..

Again, Very nice job.

Ron

RON WOODGEARD · 11-17-2003, 06:11 PM

Quote:

Originally posted by gonebad2
That is AWESOME!!!!You should get a patent on that , find someone to manufacture it as a kit. Man, you could retire.....Great Job...

That would be kinda tough, since it's Tennmans idea in the first place..????

bigvinnie · 11-17-2003, 02:40 PM

thanks for the detailed instructions... my question relates to the picture of the filler hose that routes under the frame to get to the tank... trying to understand how the fuel runs uphill to get into the tank...??? I guess the new style filler allows this to be possible...???

JadeEmperor · 11-17-2003, 02:02 AM

Great how-to, thanks for the info. Seems pretty straight forward, some items tedious but as you said I'm sure the key is checking your measurments and marks.

Keep us posted on other projects.

Iron-Butt · 11-18-2003, 10:54 PM

Thanks for the great details and pictures.

DanoDMano · 11-18-2003, 11:11 PM

Thanks for the awesome how to! I will use your demo when I do mine. Your really did a great job !!

**FRENCHBLUE72** · 11-17-2003, 09:17 AM

Thank's for the pic's and the really good nice step by step photos..

krue · 11-17-2003, 08:19 AM

Sweet job! Now I know how I am gonna do mine!
Somebody needs to make sure this and the tank install thread get put into the FAQ section!

krue · 11-18-2003, 10:02 PM

REDNEKID I think if you do a search for tennman you will see the original which was for a fleet side.

dinnut · 11-17-2003, 10:05 PM

awesome. i wanna do this. that is if i dont shave them first...

jorgensensc · 11-17-2003, 12:21 AM

Finally got around to showing the install! I hope this helps everyone. There are alot of pics, so it might take awhile to load them all.

Here is what I used:

1- 1997 S10 fuel filler door with neck
1- 1 1/2 fuel filler hose (see blazer tank install for part number)
3 ft of 5/8" hose
4- 1/4" machine threaded bolts 1 1/4" long
4- nylon lock nuts for above bolts
2- 1/2" spacers for above bolts
1- permacap gas cap (optional)
1- large can of patience!!!

Here are the parts I got from the local wrecking yard:

jorgensensc · 11-17-2003, 12:22 AM

more pics of junkyard parts

jorgensensc · 11-17-2003, 12:24 AM

sidemarker light

jorgensensc · 11-17-2003, 12:26 AM

backside of light,
You will need to grind smooth the ridges around the bolt holes on this side. Also grind off the white ridges on the ends near the bolt holes.

jorgensensc · 11-17-2003, 12:47 AM

Here is the top of the fuel filler neck. You will need to weld on an exhaust reducer fitting that goes from 2" ID to 1 1/2"OD on the bottom. I cut the filler length to just below the vent hole fitting.
I could only find a 2" ID to 1 1/2" ID so I had the fuel filler hose stretched with an exhaust pipe stretcher.

jorgensensc · 11-17-2003, 12:50 AM

Here is a pic of the sidemarker hole where the lense goes. My fender had this metal backing on it.

jorgensensc · 11-17-2003, 12:51 AM

another pic without the light.

jorgensensc · 11-17-2003, 12:52 AM

Here is the backside of the fender.

jorgensensc · 11-17-2003, 12:54 AM

You have to cut out the basket.

jorgensensc · 11-17-2003, 01:05 AM

All that is really involved is cutting the fuel door to match the width and height of the sidemarker lense. Measure between the white ridges up and down (approx. 2 1/2"), but measure to just outside the bolt holes ( about 1/8" past on both ends turns out just past 3 1/2" length). My fuel door faceplate (big round part) seperated from my hinge piece, so I had it welded together again.
You can see the weld spot on the side in this pic.

jorgensensc · 11-17-2003, 01:20 AM

Drill the holes for the lense and cut out a notch for the light. I used the original screws and just cut them off on the back side.
Now the bolt flanges on the back part of the hinge base will need to be cut off. Sorry no pics, but you will know which ones they are. They are little tabs with nuts welded on the backside. These were used to bolt the hinge on the S10. Feel free to try and make these work for you, but I couldn't, so I cut them even.

11-17-2003, 06:13 PM	#1
kaycee Registered User Join Date: Jan 2000 Location: Wyoming USA Posts: 2,446	You DA MAN!!!! Thank you very much for the installation pic's, very much appreciated.I found out that my light box has been modified a little,so that is where I was confused.Now I can weld some tabs on the front to mount the hinge to.All I had was a little tab on both ends where the light screws on now I can start working on it again.GOOD JOB __________________ 2001 Silverado K-1500 2005 FXDWG stage3 69 CHEVY Short/Step 327/4L60 373 posi 63 IMPALA 327

11-17-2003, 01:13 PM	#2
Yukon Jack Post Whore Join Date: Feb 2000 Location: Rose Hill, KS, USA Posts: 12,684	Nice detail on this. This needs to make it into the FAQ section. __________________ 1970 Blazer with a 400 sbc and 4" lift 1980 Pontiac Trans Am, 455 Oldsmobile 2012 Kawasaki Concours 14

11-19-2003, 01:31 AM	#3
toms68cst Registered User Join Date: Jun 2000 Location: Bismarck, ND Posts: 4,293	I hate to raise this question but how safe is it to have an operating light right on your fuel filler door? If I'm looking at the pictures right the light looks operational. It's not just what might happen in a minor fender-bender accident it's what might happen if the filler nozzel should damage the wiring. I'd be inclined to make it just a reflector. It seems like the potential for spark and fumes to come together exist. __________________ Unrestored 68 C-10 CST. Original 327. 4-Speed CH465. 50k or so miles. TREASURER, Drum Brake Club.

11-17-2003, 05:00 AM	#4
Longhorn Al Texas Longhorn For Life Join Date: Jun 2000 Location: Austin, Texas Posts: 698	Great job and nice truck. Oh, and nice hat! __________________ 1970 C-10 named HOSS 400SB/TH350, PS, PB, 3.07 gears \m/ Hook 'Em from Austin, TEXAS

11-17-2003, 02:40 PM	#7
bigvinnie Registered User Join Date: Aug 2001 Location: escondido, ca 92026 Posts: 1,222	thanks for the detailed instructions... my question relates to the picture of the filler hose that routes under the frame to get to the tank... trying to understand how the fuel runs uphill to get into the tank...??? I guess the new style filler allows this to be possible...??? __________________ '72 short step, 350, 700R4, tilt, ps, pdb, a/c, lowered coils, etc., other work in progress... San Diego, CA 72 Stepside Project

11-17-2003, 09:37 AM	#5
RON WOODGEARD Resident Young Old Dude ! Join Date: Jul 2001 Location: Nevada Posts: 1,948	Excellent Documentation!!! I have posted before, I am filling mine through a garden hose right now, ( not driving it on the street yet still ) I want to do just what you did, thanks for saving me a lot of time and aggravation.. Again, Very nice job. Ron

11-17-2003, 02:02 AM	#8
JadeEmperor Registered User Join Date: Aug 2002 Location: Phoenix, AZ 85018 Posts: 102	Awesome job Great how-to, thanks for the info. Seems pretty straight forward, some items tedious but as you said I'm sure the key is checking your measurments and marks. Keep us posted on other projects. __________________ Jimmie Modern Vintage Autoworks - '70 Chevy C10 - '74 Chevy C30 3+3 Dually - '04 Chevy Colorado Built, NOT, Bought. If you build it...they will ENVY! Drive Slow, Scrape Hard, or Take Your Truck and GO HOME!

11-18-2003, 10:54 PM	#9
Iron-Butt 454 club Join Date: Oct 2002 Location: Oklahoma Posts: 1,348	Thanks for the great details and pictures. __________________ David 1965 Chevrolet c-10 454 automatic Custom bbw swb. 1965 Chevrolet C-10 swb (Sold) 1963 Chevrolet C-10 6 Cyl automatic with dual exhaust, pb, ps and 17's. R.I.P "I will miss you. 1967 Chevrolet C-10 6 Cyl Custom lwb 1939 Chevrolet Coupe, 350 v8 automatic. 1935 Chevrolet 2 Dr Standard in the works. 2015 Harley Davidson Street Glide. 2023 Chevrolet Stingray Z51 Convertible. I never want to grow up.

11-18-2003, 11:11 PM	#10
DanoDMano Pronounced "Pew-al-up" Join Date: Oct 2002 Location: Puyallup, Washington Posts: 845	Thanks for the awesome how to! I will use your demo when I do mine. Your really did a great job !! __________________ Classic GM Trucks of Washington Club Member 1970 FS chevy,350/350, Edelbrock cam and intake. Holley 650 carb,HEI,AT,Tangier Orange, 18's, Power Locks, Truck Photos

11-17-2003, 09:17 AM	#11
FRENCHBLUE72 PROJECT 7DEUCE Join Date: Dec 2002 Location: GRANTS PASS OR Posts: 21,608	Thank's for the pic's and the really good nice step by step photos.. __________________ GO BIG GREEN GO DUCKS MEMBER #6377 72 k-5 daily driver 6'' lift 35'' 350-350-205 slowly getting rust free. Project "7DEUCE" check out my build http://67-72chevytrucks.com/vboard/s...d.php?t=267665 Tim Powell..R.I.P EastSideLowlife..... R.I.P..

11-17-2003, 08:19 AM	#12
krue Designated A-hole! Join Date: Mar 2003 Location: South Mississippi Posts: 36,450	Sweet job! Now I know how I am gonna do mine! Somebody needs to make sure this and the tank install thread get put into the FAQ section! __________________ "If it ain't broke, fix it 'til it is!" Being stupid ain't illegal. We're Still Debt Free Except for the House!!! www.daveramsey.com 70 GMC SWB Stepside project "Green Booger" soon to be 6.0l/4l80e 93 S-10 "Poppaw's Truck"

11-18-2003, 10:02 PM	#13
krue Designated A-hole! Join Date: Mar 2003 Location: South Mississippi Posts: 36,450	REDNEKID I think if you do a search for tennman you will see the original which was for a fleet side. __________________ "If it ain't broke, fix it 'til it is!" Being stupid ain't illegal. We're Still Debt Free Except for the House!!! www.daveramsey.com 70 GMC SWB Stepside project "Green Booger" soon to be 6.0l/4l80e 93 S-10 "Poppaw's Truck"

11-17-2003, 10:05 PM	#14
dinnut Registered User Join Date: Apr 2003 Location: missouri city, tx Posts: 4,486	awesome. i wanna do this. that is if i dont shave them first... __________________ 70 longbed 496/th400/Ford 9"

11-17-2003, 12:21 AM	#15
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	INSTALL: Tennman's Sidemarker Fuel Fill on a Stepside Finally got around to showing the install! I hope this helps everyone. There are alot of pics, so it might take awhile to load them all. Here is what I used: 1- 1997 S10 fuel filler door with neck 1- 1 1/2 fuel filler hose (see blazer tank install for part number) 3 ft of 5/8" hose 4- 1/4" machine threaded bolts 1 1/4" long 4- nylon lock nuts for above bolts 2- 1/2" spacers for above bolts 1- permacap gas cap (optional) 1- large can of patience!!! Here are the parts I got from the local wrecking yard: Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:22 AM	#16
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	more pics of junkyard parts Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE



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11-17-2003, 12:24 AM	#17
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	sidemarker light Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:26 AM	#18
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	backside of light, You will need to grind smooth the ridges around the bolt holes on this side. Also grind off the white ridges on the ends near the bolt holes. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:47 AM	#19
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Here is the top of the fuel filler neck. You will need to weld on an exhaust reducer fitting that goes from 2" ID to 1 1/2"OD on the bottom. I cut the filler length to just below the vent hole fitting. I could only find a 2" ID to 1 1/2" ID so I had the fuel filler hose stretched with an exhaust pipe stretcher. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:50 AM	#20
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Here is a pic of the sidemarker hole where the lense goes. My fender had this metal backing on it. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:51 AM	#21
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	another pic without the light. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:52 AM	#22
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Here is the backside of the fender. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 12:54 AM	#23
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	You have to cut out the basket. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 01:05 AM	#24
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	All that is really involved is cutting the fuel door to match the width and height of the sidemarker lense. Measure between the white ridges up and down (approx. 2 1/2"), but measure to just outside the bolt holes ( about 1/8" past on both ends turns out just past 3 1/2" length). My fuel door faceplate (big round part) seperated from my hinge piece, so I had it welded together again. You can see the weld spot on the side in this pic. Attached Images __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

11-17-2003, 01:20 AM	#25
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Drill the holes for the lense and cut out a notch for the light. I used the original screws and just cut them off on the back side. Now the bolt flanges on the back part of the hinge base will need to be cut off. Sorry no pics, but you will know which ones they are. They are little tabs with nuts welded on the backside. These were used to bolt the hinge on the S10. Feel free to try and make these work for you, but I couldn't, so I cut them even. __________________ 1972 C20 Suburban- Big Blue Betty '56 Chevy Bel Air Sedan- Frame up Restoration -What would you attempt to achieve if you knew you could not fail?- -I Refuse To Tiptoe Through Life, Only To Arrive Safely At Death's Door- R.I.P. EAST SIDE LOW LIFE

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