Use a uni-bit for drilling sheetmetal. Its a stepped drill bit, cone shaped, with one groove going down the side of it. You can get at your local homer depot type store for less than twenty dollars. These cut very clean holes(holes saws will not be nearly as smooth) in thin material-taking the door off won't help prevent the dent with a traditional type drill bit in my opinion.

 

Take the lock apart and fill with silicone grease. The lock will seize up from road salt migrating into the lock. I had this happen to both lower locks on my 5th propane lockers. I have never driven in snow/icy conditions.

 

This is an old post. Would really like to see the pictures, but they expired. Help is appreciated. Thanks

 

My 2015 f250 doesn't have a locking fuel door and I could find no current info on how to do this so...this is what I did. The weather resistant lock was purchased off of eBay for $10.50. As shown, it's the 5/8 depth witch worked fine. I removed the fuel door and marked everything on painters tape. I drilled two large holes in the door and then used a small half-round file to make the sides of the hole flat. This prevents the lock from twisting in the hole. After finishing the cut, I painted the raw metal to prevent rust and re-installed the door. The rubber gasket that comes with the lock is worthless so I used some RV sealant and installed the lock. Using a marker, estimate where the latch needs to be cut off to fit the door. This measurement will vary depending on where you place the lock so get the lock in first before you start chopping on the latch! I used the 1/4 turn fitting and trimmed the latch to fit. I used locktite on the screw to ensure the latch stays put.

As you can see, the lock doesn't line up straight top-to-bottom which is in the lock mechanism. The hole I cut is straight. Anyway, this took about 45 minutes

 

Looks good!

 

There are definitely like 10 different options for these now including doors that already come with locks. That's a cool mod though.

 

One small thing that I did different was to wrap the small metal piece that holds the door closed with electrical tape to help protect the paint on the inside where this piece comes in contact with the painted surface of the inside.

I also went with a barrel style keyed lock, personal preference.

 

Where have you seen ones that comes with locks? Are you taking about the replacement fuel doors?

 

Very good idea on the tape.

 

There are replacement chrome or aluminum doors sold that have a lock in them. There are like $100-125 each.

http://www.sfxperformance.com/parts/ALS6058PL.htm

ford superduty gas door lock | eBay