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When I got my 2001 Beetle last fall, the previous owner left me almost no gas. I had to use the key to pry the door open. Fortunately, it left no marks. So, my first priority was to fix it - that is until I found out what the parts cost and the labor involved. Hmm. Long ago, I owned a Fiat Spider and remember that the gas door had a little lift handle. Perfect! Apologies for not shooting this as I went along, but I'm sure you'll get the idea.

1. Buy an old Fiat Spider gas door on eBay for around $25.

http://newbeetle.org/forums/attachment.php?attachmentid=157562&stc=1&d=1423597884

2. Remove the little lift handle.

http://newbeetle.org/forums/attachment.php?attachmentid=157570&stc=1&d=1423597979

3. Use the Fiat gas door minus the lift handle as template and carefully drill appropriately sized holes in your Beelte gas door.

http://newbeetle.org/forums/attachment.php?attachmentid=157578&stc=1&d=1423598014

4. Attach the lift handle to your Beetle gas door.

http://newbeetle.org/forums/attachment.php?attachmentid=157586&stc=1&d=1423598047

5. Remove the clip that holds the release cable in place and tuck it into the hole.

http://newbeetle.org/forums/attachment.php?attachmentid=157594&stc=1&d=1423598091

6. Buy yourself a locking cap, install it, and close your Beetle gas door. Voila! A less than $50 solution!

http://newbeetle.org/forums/attachment.php?attachmentid=157602&stc=1&d=1423598131
 

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Or you can reach into the tail light access cover and unclip the spring loaded cable from the fuel door, 2 minutes and no tools needed.
 
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