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Fabricator using hand tool on blue car body.
1. MetalWorks’ talented fabricator, Dave Williams, was responsible for designing and scratch-building the cleverly hidden gas tank filler on this 1967 Chevy Nova.
Red digital stylized typography that reads HIDE & SEEK
So That’s Where the Blinker Fluid Goes
By Ron Ceridono Images by Chadly Johnson
O

ver the years automobile manufacturers have gone to extraordinary lengths to play hide and seek with the fuel tank filler. Cadillac went so far in 1949 to conceal it under the hinged driver side taillight. Chevrolet did the same thing in 1956 with a unique flip-down taillight. For those old enough to remember hiding the gas cap, this was not only a slick styling trick, it was also the origin of a classic gas station gag. There was always an old-time pump jockey who would flip open the taillight of one of these cars and tell the new kid at the service station “that’s where you add blinker fluid.” No telling how many trusting young men were sent to a parts house to ask an amused salesman for a gallon of the stuff.

Recently we were talking to Chadly Johnson, our man on the scene at MetalWorks Classic Auto Restoration in Eugene, Oregon, when he mentioned they were installing a hidden gas tank filler behind the taillight of a 1966 Chevy Nova. That sounded like a cool idea, but what piqued our interest was hearing this was not a kit. All the modifications made to modify the taillight and hide the fuel filler were designed and fabricated by their own Dave Williams. We had to see how it was being done.

Williams began the transformation by removing the inner support structure of the original taillight. He then fabricated a housing from sheetmetal to mount the fuel tank’s relocated fill pipe. A hinge was fabricated from flat stock that mounts an LED taillight that now swings open to access the gas cap. A cable-operated gas door latch from a Nissan holds the light tight to the body when in the closed position. All of these modifications required some crafty engineering.

With the modified taillight/gas filler assembly in place, Williams turned his attention to filling the hole that was left in the quarter-panel; more precisely the two holes that were left, as there was one in the inner fender panel and another in the outer skin. The inner hole was simply filled with a round patch, but the outer panel was more complicated. The factory stamping caused a slight distortion in the panel, and to blend the area to Williams’ satisfaction, a larger patch panel was necessary.

Like everything MetalWorks does, this hidden fuel filler was perfectly executed. It’s a modern version of the classic gas cap hide and seek, but where the blinker fluid goes is anyone’s guess.

Taillight housing swung open to reveal hidden gas filler.
2. The relocated gas filler uses a Tanks self-sealing cap. The fuel pump nozzle is inserted through the spring-loaded “door” in its center.
Open taillight pocket on blue rear quarter panel.
3. Here the stock taillight has been removed. Note the two large holes, the upper is for the taillight/turn signal wires, the lower is for the backup light wires.
Original metal taillight support structure removed from car.
4. This is the taillight support structured removed from the fender.
Cardboard templates and raw sheet metal for inner structure.
5. Williams made a cardboard pattern, then fashioned a new inner structure from 12-gauge sheetmetal to mount the relocated fuel filler.
Bent metal mounting plate with rectangular hinge cutout.
6. Here the ends of the mounting plate have been folded and a hole cut for the hinge that will attach to the taillight.
Welded recessed box on metal mounting plate.
7. A recessed box to house the gas cap was added to the back side of the hinge mounting plate.
Gas cap sitting inside the fabricated metal housing.
8. It’s a tight fit for the Tanks gas cap in the recess, however it doesn’t have to be removed during fill-ups.
Rear view of fabricated gas filler tube assembly.
9. On the back side of the gas cap recess is a tube that will connect to the gas tank’s stock filler location.
Custom steel hinge assembly sitting on welding table.
10. To mount the taillight assembly, Williams made a hinge for ¼x1-inch steel flat stock.
Welded hinge mounting tabs on the metal structure.
11. A pair of mounting tabs for the hinge were added to the mounting plate.
Testing the hinge swing with the gas cap installed.
12. With the gas cap in place, the hinge was installed to check its swing. So far so good.
Metal pocket box fitted into the fender opening.
13. With the hinge figured out, the box was fit to the opening in the fender.
Interior mounting brackets for the hinge mounting plate.
14. To hold the hinge mounting plate in place, brackets that attach to the body were added. Here the bottom bracket can be seen.
Filler assembly bolted into the interior of the car.
15. Attached to the gas tank recess is the top bracket that bolts to the body.
Billet aluminum LED housing next to mounting plate.
16. On the left is the billet aluminum LED taillight housing. Note the two holes for the factory wiring. On the right is the mounting plate that will attach to the hinge.
Rear side of taillight unit showing wiring exit.
17. Here, the mounting plate has been attached to the taillight. All the wires now come out of a single hole.
Taillight housing attached to the hinge.
18. After some careful fitting, the taillight mounting plate was attached to the hinge.
Black painted hidden filler assembly in the open position.
19. This is the completed hidden filler assembly with the taillight in the open position.
Gas cap latch mechanism installed on the housing.
20. Mounted on the right side below the hinge is a Nissan gas cap latch the holds the taillight in the closed position.
Completed taillight assembly protected by yellow masking tape.
21. Here’s the completed taillight assembly without the lens, in place. The billet housing is covered in tape to protect it during the fabrication process.
Custom LED taillight unit on bench.
22. LED taillight/backup lights with billet aluminum housing replace the stock units. They’re not only brighter, the housings are thinner, making them better suited to being hinged.
New black fuel tank for EFI applications.
23. The replacement gas tank is equipped with an EFI pump. The tank’s inlet is in the stock location. It connects to the filler with a custom tube.
Welded circular metal patch on the inner panel.
24. With the stock gas filler removed, the hole in the inner panel was filled.
Taped-off area for quarter panel patch.
25. Filling the hole in the quarter-panel was more challenging. To get the right contour, Williams cut and filled a larger hole.
Finished metalwork on rear quarter panel.
26. The finished quarter-panel modification blends in much better than would have been possible with a smaller patch.
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MetalWorks Classic Auto Restoration