I got a fuel door repair kit from IPD it seems in all the reviews they will brake when you try to punch the new plastic pieces in....any one got any tips to prevent this???

 

Try removing the 4 pins prior to mating the hinge up to the body. Then insert a pin and tap it into place. Repeat. I think most people skip right to whacking away at the pins.

 

I could only get the two outside (I think) pins in. The others were to tight. I ended up finding a couple of screws that were the same diameter and used those to bolt mine on. Much more secure.

 

This is really a pain and I don't know why that plastic repair peice isn't made a bit better. I ended breaking 3 clips off but I used super glue to secure it to the body and it also reinforces the clips that did snap in properly. it's been on for a year through summer and winter and is strong as ever. Sounds tacky but works. Make sure not to get the glue on your car paint where it is visible.

 

well i managed to get all the pins in without breaking a single one...I took a pair of pliers and pulled the pins off of the replacement hinge then took a punch and taped them in, though my efforts were futile as soon as i got the pins in and shut the door to make sure it was ok...the plastic that the door snaps into (which is the thing that broke in the first place) snapped right off! so now i have to get a new one and try again!

 

I installed a new fuel door hinge on one of my Volvos recently and also broke one of the pins. I just punched out the broken pin and found an appropriate sized sheet metal screw to hold the hinge in and it works fine.