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Gas Cap Troubles

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Michael Valentine

Joined: 09 Jan 2006
Posts: 108

Posted: Mon Jun 19, 2006 6:58 pm Post subject: Gas Cap Troubles

Listers -



I was excited to learn that ZAC had updated the gas cap design from

the old method of just leaving the skin flush with the hole.

Unfortunately, when I went to screw the cap into the tank, I

discovered that it does not go down far enough.  The cap sticks up 2-4

mm all around the rim.  I only have one layer of cork on top and

bottom of the tank and the skin is quite taut all around - I

definitely can't shim underneath the skin to push it up flush against

the rim of the cap.



Has anyone else had a similar problem?  Is the insert welded into the

tank too high? (Come to think of it, I suppose it could also be welded

at a bit of an angle, too, because it is not quite the same distance

above the skin all the way around.)  Can I buy a new cap with a lower

profile?  Any help greatly appreciated!



Thanks, Michael Valentine



601XL - Almost, but not quite done with the first wing (and I've been

saying that for at least three weeks).

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Posted: Tue Jun 20, 2006 6:13 pm Post subject: Gas Cap Troubles

Michael,

                I went through the exact same problem recently. The cap(s)

was not only too high, but also was warped way out of  alignment from the

welding process. Here's how I fixed it.

        1 - I reduced the cork to the minimum possible thickness on the

bottom, but gained very little.

        2 - I used a mallet and hardwood block right on top of the filler

opening, focusing on the highest side, using a metal yardstick across the

opening and tank top to check progress. You have to hit it really hard, but

this is very effective. Neither of my tanks were damaged by this procedure.

I was able to align the filler well with the skin, and drop it

significantly.

        3 - A little bit more recess was needed, so I filed and ground a

bevel in the opening that matched the angle of the outer cap piece, allowing

it to thread in deeper before bottoming.  The threads take a bit of tender

loving care, and of course the tank interior needed a good vacuum job.

               All of this only took about an hour for both tanks and solved

the problem, but it sure was hard  to clobber my tanks like that!

                                                                    Lynn

                                                                    Corry,

PA

                                                                    601XL

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