Topic: Aftermarket fuel caps

[754]

If I were installing the bolt in version, I would;
 Cut a piece of 3/8 in or 5/16  steel or aluminum the width of the hole in tank x  the diameter of the bolt flange, drill and tap to 3/8 NFor bigger. Now make a top piece same width or wider, dont need to round ends, but put thru hole in the middle for bolt.
 Slip in rounded tapped piece, inside tank (you may need to hold it with a piece of tape or string)  then put top piece on, insert bolt and tighten.. then slack off bolt and turn and repeat. It should? flatten the top area where the flange sits. do it gently..

[q2418130103p]

If I were installing the bolt in version, I would;
 Cut a piece of 3/8 in or 5/16  steel or aluminum the width of the hole in tank x  the diameter of the bolt flange, drill and tap to 3/8 NFor bigger. Now make a top piece same width or wider, dont need to round ends, but put thru hole in the middle for bolt.
 Slip in rounded tapped piece, inside tank (you may need to hold it with a piece of tape or string)  then put top piece on, insert bolt and tighten.. then slack off bolt and turn and repeat. It should? flatten the top area where the flange sits. do it gently..

That is almost exactly what I was planning to do, I think.

The top of my tank is fairly flat, but will probably require some gentle love.

My fear with this plan is that it could distort the surrounding area. 

I was also thinking about taking a dolly, griding a ridge in it, and using that with a hammer to make a recessed ridge for the flange to fit into.  I dont think I described that very well...  I am going to talk it over with my father, he is far better at that sort of thing than I am.

[Bakeoff]

There are bunch of cool and cheap billet caps for modern sport bikes on ebay now.  Like this one...



Find a beat up tank where the cap area is salvageable for next to nothing, and then find the cap to match.

[q2418130103p]

Good thinking, I should go visit the scrap yard first.

Are they usually bolt on?

[q2418130103p]

So I got a cap from custom cycle engineering for $165.

It came in packaging with there name on it.

On the bottom of the cap it says Newton Equipment.  Turns out this is the same unit as the Aero 300 from Newton.  Except when it is branded from newton is costs $300!!

Check it out: http://www.fuelsafe.com/store/afc200a.html