How easy is it to fix an Aircraft filler cap to me tank ???

[Steel Draconian]

I want to remove the old locking filler cap 'n' fix an aircraft one. Is it just a matter of drill, cut n fit? :confused:

[m@rk]

a few years back..(probly more than i want to know)..bsh did a non techie guide to fitting one with photos n all.
im sure someone else hear will remember and may still have it...
from what i remember it wasnt to difficult either... :)

[Dougie]

AWoL did one too.

[madpigpunk]

Got both those articles smowhere will try and dig them out.The general jist is use the gasket supplied with cap as a template.Mark out where its going, preferably on a flatish surface.Cut the hole with either a hole cutter or chain drill and file it.drill the holes for mounting bolts and fit.Remeber hearing a tip that the nuts were a bugger to get on the backand to tie your spanner to a bit a string so you aint gotta keep rattling the tank around to get your spaner out.Also dont forget to flush out the tank cos it will be full of metal fillings that carbs dont like one bit.Also you will now need to fit a one way breather to the tank as you sealed it with the cap and created a vacuum.Hope this Helps
Paul B :)

[Dougie]

Another tip,put some tape on the back of the spanner to hold the nuts.

[eddie axeman]

if u use a hole saw they rely on the pilot drill to keep them central u will not be able to use a pilot drill but some hole saw arbours have extra thread on them so u should be able to screw a smaller hole saw the size of the exsisting hole on the end of the arbour

[Steel Draconian]

Thanx Lads! Notes taken 'n' will let ya know how it went????

[Blackjack]

Tip for using a hole saw is to cut out a hole in a piece of scrap first. Then use the "washer" from that hole and tack/glue/solder it to the neck of the tank which provides location for the pilot.

Another tip is to use a piece of 1/4" rod instead of the drill bit as a pilot. reduces the likelihood of the saw wandering around and making an oversize hole, which if you're fitting the smaller size cap is a bummer.

Last thing, don't forget about the breather situation.

[guydewdney]

cant be that difficult - i did one on a SR250 tank on my Z200 streetfighter aged 18 - in my garage with just a drill.... so you should have no prob mate ;)

(z200, 250 crank, z1000 con rod, double oil pump, outside oil feed, rgv usd forks, zxr400 yokes, rgv monoshock back end, honda 125 3 spoke wheels...handled like a p*ssed walrus lol)

[Doro]

please can I have the rest of the aeroplane?

[minxy]

I'm having that done!

Cnat help though coz its all in the hands of The Jester :D