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A good thing about these is that the stainless steel is really hard and forms a strong metal memory, and will almost return itself back into shape. Little work with a hammer and you can watch these come back into shape right in your hands.

If you have a pump with the hinge broken broken off, here's an easy way to fix it. Get 3 #10-24 flat top screws, these are the same size as the screws that screw into the frame. Grind the old spotwelds off of the hinge. Clamp the hinge into position on the door. Drill through the hinge and the door. Using a countersink bit, carefully enlarge the hole on the hinge until the head of the screw sits flush with the inside of the hinge. You can now put a nut on the inside of the door, and the hinge can close without interference from the screws.

Ok, back at it. With the hinge attached, I can test fit it back on the pump. The alignment is good. There really isn't a good way to adjust the alignment on these doors. You have to physically bend the metal until the alignment is where you want it. Again, good's worst enemy is better in this situation.

With the fit good, I got out the polishing wheel and compound. This stainless is super hard, and it is super hard to polish. I'm getting it to brighten up though.

With the door brighten up, I can install the window. I chose acrylic for this. I believe it was acrylic originally. I have always avoided glass on these pumps because I feel the door is too flexible, and could stress and brake glass easily. This is just my theory, please feel free to disagree. I could have used the rubber that I used on the Ad glass, but here I'm using another option. This is double sided tape used to hold trim and emblems on modern cars. I got this at an auto body supply shop. If you've never seen or used this stuff, let me tell you it is CRAZY strong. I have bent fenders and hoods trying to pull emblems off of cars in the junkyard that were held on by this same material. I had considered using this to hold the ad glass in, but used rubber there. I peeled the tape off the roll and put it on the inner flange of the door. Then I peeled the backer off, and just stuck the acrylic in place. Just like that, done.

With the window in, now is time for the lock. I didn't have a key for the originals (yes, I looked, i was an actual gas pump mechanic for years and used to service Waynes. I have quite the collection of pump keys in my collection) The originals are probably frozen anyway. I found this lock set at that big box store that likes the color blue. It is nearly identical to the original. I installed the cylinder and the blade.

Now that the lock is installed, there are a few minor adjustments that need to be made. There is not quite enough tension on the blade to hold the door shut all the way. Taking the blade off and giving it a few tweaks with a hammer should help.

You can also bend the tab on the frame in or out to adjust the tension on the door.

There, that's better. Now the door closes tightly.

Only one part left. I had this nozzle laying around, so that's what I'll use. I used to use real gas pump hoses, but they are really stiff and don't hang well. Also they are too long. I'd have to use the hose retractor, and I don't care for using them because the hose and the hardware rubs up against the pump. I used heater hose here because it's soft, flexible, short and hangs nicely.

And here's the final result.

Upper view

Sweet conclusion - thanks for sharing your journey…BTW - is that a Joker Poker lurking in the background?

Thanks for taking the time to document this project! The pump has a good look to it.

I've enjoyed following along with your restoration, thanks for taking the time to post it.