Background
Filler lid cutout and gas cap location
The right fiberglass quarter panel is designed to incorporate the original gas filler lid assembly. This assembly includes a remote lid release latch and a rubber surround for the filler pipe/gas cap.
The fiberglass lid seat profile is close to the plastic original, but not quite. It is difficult to get the contours to exactly match the lid assembly, and the location of the cutout above the gas cap may not be precisely right.
Due to these fitment issues, an alternative fabrication method is described below.
You had me at “frenching”. Good idea! I will try this on my next Beetle Ute!