INSTALL: Tennman's Sidemarker Fuel Fill on a Stepside - Page 2 - The 1947 - Present Chevrolet & GMC Truck Message Board Network

jorgensensc · 11-17-2003, 01:26 AM

Here comes the hard part. Drill 2 holes in the lip of the hole on the fender (where the light goes) These will be used to mount the hinges in place. While your at it drill the holes on the opposite side also. These holes will be used to hold on the plastic fuel tray.

jorgensensc · 11-17-2003, 01:33 AM

Next hold the assembly (hinge assembly with lense attached) up in the hole. You need to open and close the assembly while holding it in place to get the alignment right. The best way is to hold the hinge underneath while the lense is in the right spot. Have your helper open the door slowly and then mark the through the holes you drilled in the lip to the hinge. TRIPLE CHECK YOUR MARKINGS!!!!!!! I cannot stress that enough. Then pull the assembly and drill the holes. Make sure they line up appropriately after you drill them. Next bolt it in. I had to add some washers as spacers between the fender and the hinge to help bring the back half of the hinge more flush.

jorgensensc · 11-17-2003, 01:34 AM

Here it is installed:

jorgensensc · 11-17-2003, 01:35 AM

Another (again)

jorgensensc · 11-17-2003, 01:45 AM

Next bolt on the fuel tray to the filler neck.
I actually bolted on mine upside down, with the hole in the filler neck towards the top. This makes it easier to fill with gas. I tried it the normal way, but there is not much room, so this was the fix. It doesn't seem to affect anything. Hook up the hoses (the filler hose and the vent hose). Next hold the assembly (filler neck with tray) up to the hole. Find where you will need to trim the tray, then pull the tray off and trim what you need to trim. You will need to do some trial and error here. What I did was leave it loose, take it to the gas station, Insert the gas nozzle, then mark the location of the tray. I also marked the holes I drilled earlier on the fuel tray.

jorgensensc · 11-17-2003, 01:51 AM

Heres another of the filler neck installed. The Blazer tank inlet and the filler neck match almost perfect. When I installed the fuel tray I added spacers between the tray and fender. Once again to give a little more room when adding fuel.

jorgensensc · 11-17-2003, 01:56 AM

Drill the holes in the tray for the bolts (once again TRIPLE CHECK before you drill. There isn't alot of room to play with on the tray. You might need to do a little 'tweaking' and bending to get everything to line up properly.

jorgensensc · 11-17-2003, 02:03 AM

Make sure when you open the door, the lense doesn't hit the side of te bed. I remedied this by bending the hinge a little, so it didn't open to a full 90 degrees.
Here is the reason for the Permacap:
I installed everything and put the regular gas cap on and put the light in. The light harness hit the gas cap. So I got the permacap because it has a lower profile. Now the light clears just fine. I still have to remove the cap to fill the tank (California gas nozzles have huge adapters on them and they won't fit in the light hole well). But I really don't mind much.
Here are some pics of the final product:

jorgensensc · 11-17-2003, 02:04 AM

more

jorgensensc · 11-17-2003, 02:06 AM

Another

jorgensensc · 11-17-2003, 02:07 AM

One More

jorgensensc · 11-17-2003, 02:12 AM

Since they seem to go together, here is the link to the blazer tank install:
BLazer Tank Install

Also I put a new light harness in and zip tied it discreetly to the hinge after I wrapped it in electrical tape.
Hope you enjoyed this post!!!
It's really not that hard, just tedious and it takes a little tweaking.
If you have any questions, please feel free to ask!
Shawn

jorgensensc · 11-17-2003, 09:45 PM

Thanks for all of the support guys!!!
I hope no one thinks this is my idea!!! I just modified Tennman's install for a stepside.
Bigvinnie,
It is only a slight uphill slant, and the force of the gas going through the nozzle pushes it through just fine. I have yet to have it back up on me.
Thanks again for the encouragement!!!
Shawn
P.S. I don't know if Josh decides about what goes to the FAQ section, but I think both the blazer tank install and this install would be good candidates.

REDNEKID · 11-18-2003, 06:43 PM

Awsome work bro, any idea how I would adapt this to work on a fleetside?

jugernot · 11-17-2003, 02:21 AM

Wow that is really really cool. Great job thanks for sharing.

howell57 · 01-15-2019, 08:08 PM

Can this be done on a fleetside? Not much room between marker light and inside wall.

Duner97 · 05-31-2020, 11:30 AM

It can be done with a little bit of cutting. I was a 19 year old with a grinder and a welder that saw this thread back in 03 or 04. Now, California emissions laws require big ol rubber boots on the fuel pump spigots, and makes filling the truck a little difficult. I need to carry around a little adapter to stick into the neck when I refuel. If I had to do it again, I would use the tail light.

gonebad2 · 11-17-2003, 05:11 PM

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

**72afr** · 11-17-2003, 11:55 PM

all i gots ta say is you da man

**72afr** · 11-19-2003, 01:35 AM

i dont think that you can have just a reflector on a 72, at least in MO, if they came with a light, i think that they have to have them (if i remember right)

BLACK AND BLUE 67-72 · 11-19-2003, 11:48 AM

I wouldn't worry too much about the wiring causing any problems during an accident, because any fumes that were being vented would be carried away by the airflow that the truck would have while moving, besides they don't really vent enough fumes to cause a problem.

And thanks for the detailed install jorgensensc, Great job on the stepside conversion!!!!!!

jorgensensc · 11-20-2003, 12:33 AM

toms68cst,
Your not the first to ask me this question!!I will say that I feel very secure with this setup. I will say that the as nozzle doesn't come anywhere near the light itself. Remember that you open this door regularly and would probably notice if the wires were exposed. My last point is that in tank fuel pumps have power that goes all the way into the tank. This is safer than that, IMO!!!!! Thanks again for the props!!!

krue · 11-20-2003, 10:15 AM

Thanks to Rod and Josh this thread and the tank install are now part of the FAQ.

Great job Jorgensc

Bowtiefreak · 11-20-2003, 11:09 AM

jorgensensc-
Great explanation of this install. This will help everyone.
Thanks

bluec10 · 11-21-2003, 01:09 AM

Outstanding! This is exactly what I want to do. I appreicate the effort you went thorough to post this stuff.

Some guys build a kind-of box inside the bed behind the marker light for the filler pipe. I'm glad to see that you didn't do that.

11-17-2003, 01:26 AM	#1
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Here comes the hard part. Drill 2 holes in the lip of the hole on the fender (where the light goes) These will be used to mount the hinges in place. While your at it drill the holes on the opposite side also. These holes will be used to hold on the plastic fuel tray. 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, 01:33 AM	#2
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Next hold the assembly (hinge assembly with lense attached) up in the hole. You need to open and close the assembly while holding it in place to get the alignment right. The best way is to hold the hinge underneath while the lense is in the right spot. Have your helper open the door slowly and then mark the through the holes you drilled in the lip to the hinge. TRIPLE CHECK YOUR MARKINGS!!!!!!! I cannot stress that enough. Then pull the assembly and drill the holes. Make sure they line up appropriately after you drill them. Next bolt it in. I had to add some washers as spacers between the fender and the hinge to help bring the back half of the hinge more flush. __________________ 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, 01:34 AM	#3
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Here it is installed: 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, 01:35 AM	#4
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Another (again) 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, 01:45 AM	#5
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Next bolt on the fuel tray to the filler neck. I actually bolted on mine upside down, with the hole in the filler neck towards the top. This makes it easier to fill with gas. I tried it the normal way, but there is not much room, so this was the fix. It doesn't seem to affect anything. Hook up the hoses (the filler hose and the vent hose). Next hold the assembly (filler neck with tray) up to the hole. Find where you will need to trim the tray, then pull the tray off and trim what you need to trim. You will need to do some trial and error here. What I did was leave it loose, take it to the gas station, Insert the gas nozzle, then mark the location of the tray. I also marked the holes I drilled earlier on the fuel tray. 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, 01:51 AM	#6
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Heres another of the filler neck installed. The Blazer tank inlet and the filler neck match almost perfect. When I installed the fuel tray I added spacers between the tray and fender. Once again to give a little more room when adding fuel. 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, 01:56 AM	#7
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Drill the holes in the tray for the bolts (once again TRIPLE CHECK before you drill. There isn't alot of room to play with on the tray. You might need to do a little 'tweaking' and bending to get everything to line up properly. 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, 02:03 AM	#8
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Make sure when you open the door, the lense doesn't hit the side of te bed. I remedied this by bending the hinge a little, so it didn't open to a full 90 degrees. Here is the reason for the Permacap: I installed everything and put the regular gas cap on and put the light in. The light harness hit the gas cap. So I got the permacap because it has a lower profile. Now the light clears just fine. I still have to remove the cap to fill the tank (California gas nozzles have huge adapters on them and they won't fit in the light hole well). But I really don't mind much. Here are some pics of the final product: 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, 02:04 AM	#9
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	more 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, 02:06 AM	#10
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Another 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, 02:07 AM	#11
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	One More 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, 02:12 AM	#12
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Since they seem to go together, here is the link to the blazer tank install: BLazer Tank Install Also I put a new light harness in and zip tied it discreetly to the hinge after I wrapped it in electrical tape. Hope you enjoyed this post!!! It's really not that hard, just tedious and it takes a little tweaking. If you have any questions, please feel free to ask! Shawn 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, 09:45 PM	#13
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	Thanks for all of the support guys!!! I hope no one thinks this is my idea!!! I just modified Tennman's install for a stepside. Bigvinnie, It is only a slight uphill slant, and the force of the gas going through the nozzle pushes it through just fine. I have yet to have it back up on me. Thanks again for the encouragement!!! Shawn P.S. I don't know if Josh decides about what goes to the FAQ section, but I think both the blazer tank install and this install would be good candidates. __________________ 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

11-18-2003, 06:43 PM	#14
REDNEKID Who said that? Join Date: Aug 2003 Location: HOUSTON, TX. Posts: 106	Awsome work bro, any idea how I would adapt this to work on a fleetside?

11-17-2003, 02:21 AM	#15
jugernot Life, Be In It..... Join Date: Oct 2003 Location: Novato, California Posts: 1,498	Wow that is really really cool. Great job thanks for sharing.



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01-15-2019, 08:08 PM	#16
howell57 Registered User Join Date: Sep 2018 Location: Redding, Calif. Posts: 101	Re: INSTALL: Tennman's Sidemarker Fuel Fill on a Stepside Can this be done on a fleetside? Not much room between marker light and inside wall.

05-31-2020, 11:30 AM	#17
Duner97 Registered User Join Date: Jul 2002 Location: Arroyo Grande, CA Posts: 125	Re: INSTALL: Tennman's Sidemarker Fuel Fill on a Stepside It can be done with a little bit of cutting. I was a 19 year old with a grinder and a welder that saw this thread back in 03 or 04. Now, California emissions laws require big ol rubber boots on the fuel pump spigots, and makes filling the truck a little difficult. I need to carry around a little adapter to stick into the neck when I refuel. If I had to do it again, I would use the tail light. Attached Images __________________ 72 SB 4x4 -Duner97

11-17-2003, 05:11 PM	#18
gonebad2 Merciless Butcher Join Date: Oct 2003 Location: CC Nevada Posts: 1,447	That is AWESOME!!!!You should get a patent on that , find someone to manufacture it as a kit. Man, you could retire.....Great Job... __________________ Your Bought And Sold....I Got Your Soul!

11-17-2003, 11:55 PM	#19
72afr Beep! Beep! Join Date: Nov 2003 Location: Rural, MO Posts: 284	all i gots ta say is you da man __________________ 1972 Chevrolet C/10 shortbed, stepside, 350, HEI, Fire Engine Red, Black Interior, Former Army cargo transport 2003 Chevrolet 2500HD CC 6.0 4wd 2004 Jeep Rubicon some aftermarket stuff... 2019 Jeep Unlimited Rubicon (the wife's baby hauler)

11-19-2003, 01:35 AM	#20
72afr Beep! Beep! Join Date: Nov 2003 Location: Rural, MO Posts: 284	i dont think that you can have just a reflector on a 72, at least in MO, if they came with a light, i think that they have to have them (if i remember right) __________________ 1972 Chevrolet C/10 shortbed, stepside, 350, HEI, Fire Engine Red, Black Interior, Former Army cargo transport 2003 Chevrolet 2500HD CC 6.0 4wd 2004 Jeep Rubicon some aftermarket stuff... 2019 Jeep Unlimited Rubicon (the wife's baby hauler)

11-19-2003, 11:48 AM	#21
BLACK AND BLUE 67-72 Firefighter Join Date: Feb 2001 Location: Yellville, Ar, USA Posts: 1,943	I wouldn't worry too much about the wiring causing any problems during an accident, because any fumes that were being vented would be carried away by the airflow that the truck would have while moving, besides they don't really vent enough fumes to cause a problem. And thanks for the detailed install jorgensensc, Great job on the stepside conversion!!!!!! __________________ '72 Chevy SWB 350 Auto '67 GMC LWB 350 4 speed '70 Chevy 4x4 Stepside 350 Auto Yellville, Ar. USA Last edited by BLACK AND BLUE 67-72; 11-19-2003 at 11:52 AM.

11-20-2003, 12:33 AM	#22
jorgensensc Registered User Join Date: Jul 2003 Location: Cypress, Tx Posts: 4,005	toms68cst, Your not the first to ask me this question!!I will say that I feel very secure with this setup. I will say that the as nozzle doesn't come anywhere near the light itself. Remember that you open this door regularly and would probably notice if the wires were exposed. My last point is that in tank fuel pumps have power that goes all the way into the tank. This is safer than that, IMO!!!!! Thanks again for the props!!! __________________ 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

11-20-2003, 10:15 AM	#23
krue Designated A-hole! Join Date: Mar 2003 Location: South Mississippi Posts: 36,448	Thanks to Rod and Josh this thread and the tank install are now part of the FAQ. Great job Jorgensc __________________ "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"

11-20-2003, 11:09 AM	#24
Bowtiefreak Registered User Join Date: Jul 2003 Location: LeRoy, Mich. Posts: 854	jorgensensc- Great explanation of this install. This will help everyone. Thanks __________________ 1968 Chevy C10 Short Fleetside/Wood floor ECE 4-6 Drop / 406 Small Block 1971 Chevelle 427 Big Block

11-21-2003, 01:09 AM	#25
bluec10 Registered User Join Date: Apr 2002 Location: Manitoba, Canada Posts: 663	Outstanding! This is exactly what I want to do. I appreicate the effort you went thorough to post this stuff. Some guys build a kind-of box inside the bed behind the marker light for the filler pipe. I'm glad to see that you didn't do that. __________________ Present: 2015 Tacoma. Yeah, not a GM, but I love it. 1969 GMC 32,000 - fix, drive, relax, fix... 2019 BMW R1250 GSA - Yahoooooooo 1979 Honda GL 1000 - retro touring at its best. Past: '05 Sierra 4x4 - Had 270,000 KM and running well when it was written-off by a stop sign runner. '94 F-150 from the "F word" company. I'll admit it...good truck. Sold what was left of it for $800 to a guy who came to pick it up at 11:00 PM with cash in hand. Hmm. '79 Sierra Grande (Black) organ donor - perfect rebuildable 4-bolt 350 and a good TH350. '76 Sierra Grande (Orange) - hate isn't too strong a word. Kid who bought it turned it into a hot rod. '68 C-10 R.I.P. - Dad's old truck...too far gone to resurrect. '59 C-50 - with hoist. Truck is gone, wife isn't. Nuff said. Last edited by bluec10; 11-21-2003 at 01:18 AM.

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