Picture DSC00844 of the ICE gas tank filler opening and the door cover. BMW calls the door a "fill-in flap" (part # 51171960024). The rubber "gasket" (picture DSC00989 has already been removed).
Picture DSC00989 of the fill port gasket seated in the opening of the gas tank filler after removal of the gas tank fill door from the side of the car. BMW calls this OEM rubber piece a "rubber cover" (part # 51711977597).
Picture DFSC00991 showing the side view of the rubber gasket after removal from the filler opening.
Picture DSC00994 showing the grommet like groove that extends around the circumference of the gasket.
Picture DSC00995 showing the installed "OEM" style gasket after cutting away the internal portion.
Picture DSC00976 showing the outside view looking distal and into the gas fill port prior to removal of the protruding hardware on the wall of the trunk compartment.
Picture DSC00975 showing the internal view (looking out) of the fill port. Note the protruding structure (with washer) attached to the body of the car at the right below center. This BMW structure was used to mount the gasoline expansion tank.
Picture DSC00986 after using a grinding wheel to remove the internal mounting hardware. The J1772 adapter would not fit until this BMW structure was removed.
Picture DSC01001 of the hinge mechanism prior to disassembly. Two M6 welded studs protrude from the backside of the hinge.
Picture DSC01002 showing the spring after prying it out of the center support clip.
Picture DSC01004 after sliding the mounting pins to the left and out of the hinge holes. The studs were then drilled out to accept 60 mm long M6 bolts.
Picture DSC01008 showing the milled out Aluminum adapter that was made from a 1.75" thick billet . Dimensions are in inches. The bottom mounting surface for the J1772 was 3/16" thick. Top to bottom internal cavity was 4", left to right internal was 4.75 ". The pilot holes for the left side mounting bolts were 16/32" from the inner edge. The left wall was 29/32" thick and the right wall was 1 9/16" thick. The center inner through hole permits the cable end (backside) of the J1772 to pass completely through was 2 5/32" diameter. Although the use of a rotary table on the Bridgeport mill made the operation very efficient, it is somewhat embarrassing how many hours were spent making the part. This piece could be used to fabricate a mold from which additional pieces can be produced at a foundry. If anyone is interested please drop an email to William at sales@narchem .com
Picture DSC01013 showing the mounted J1772 socket. The black dot at the left below center is a BMW OEM grommet that cushions the closing of the fuel door.
Picture DSC01012 showing the internal plastic cap of the J1772 full open.
Picture DSC01009 showing the door fully closed and flush with the car sides. When closed the door makes a solid sound as it seats against the black rubber gasket. The necessary body work and repainting of the car will be a later project after the EV is mobile.
Picture DSC01019 showing the side view of the J1772 recharging port. Take note of the wording of the warning label on the door in the "before" picture DSC00844 at the beginning of this posting, and compare the current wording of the warning label on the door in this "after" picture.
