The original owner had relocated the tank between the frame rails in front of the rear bumper. There's a sturdy skid plate under it. Note how the filler neck winds its way to back right corner.
This three inch hole is not for a tail light. Those two nickel sized ones are. No, that large one is for a relocated fuel filler hole.
First, I ground the welds smooth along the body seam.
Then I overlaid the filler neck housing. It'll fit perfectly between the pinch weld that connects the right rear quarter panel to the back body panel and the tailgate reinforcement flange.
A jigsaw made quick work of the hole.
I took off a little less than what I needed at first. That pinch weld had to be ground down some to get the flanges to fit flat.
My first test fit.
I'm particularly happy that this will cover up where my long patch panel meets the pinch seam.
My hole punch worked nicely here.
Clean metal to weld in plugs.
Smooth flange meets lumpy sheet metal. A good squeeze got the bottom flange to sit flat.
As I worked my way around, I put some weight behind it to hold it flush.
Ground smooth and primered. Looks almost stock, I think.
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