I kept my doors locked during my "operation" as well......it makes taking hold of the plunger so much easier with that little extra bit sticking out.

Hey guys, I am so close. How did you get the plunger back onto the new S cap?

If I recall correctly (it's been almost a year since I did it), I taped some fishing line to the plunger to help ease it (barely) up through the hole, then grabbed and pulled it the rest of the way through.

Thanks Komet. I actually ended up doing something similar I used twine and tied it to the plastic locking mechanism. I cut off most of the twine, but there is some stuff back there.

Unfortunately, my car ended up with a couple of small battle wounds (small dent and small paint chip. I am 99.9% sure the small dent was from wrestling the old gas pot out of the car :mad:

OUCH! Sorry to hear that. I feel your pain since my mountain bike fell against my door 4 months after I got my "Justa" and I had to have a paintless dent repair guy work it out. $80 well spent IMHO.

The Good, The Bad and the Ugly
 

Unfortunately, the painted plastic trim piece is not uniformly flush all the way around. 5-7 O'clock positions stick out a bit, and even with pushing evenly across the entire trim piece, I am unable to get it to budge any further.

In the second photo, you can see the small nick I created from a screwdriver that ripped through the masking tape. I also created a small dent, which was probably from wrestling the old assembly out. I will probably get it fixed at a paintless dent removal place down the road.

Mine didnt fit perfectly flush at first either, similar to how you describe yours, but in time it's gotten better or perhaps I just dont notice it anymore.