Aircraft style flush mount fuel cap

[opelenvy]

Well I got tired of the high price of the used stock gas caps, and to be honest I'm not that fond of the "wind up" look. So I decided to do this. I researched several different options and ended up with the motorcycle cap. I got a 2.5" to 2" pipe at O'Reilly's and had a local welder make a flange on it that matched the cap. I drilled out the holes and had to buy longer stainless steel screws that would fit through the flange. The holes are right on the edge of the hole and could easily go back to stock and be filled and covered by the original rubber. I put nylock nuts on the back and rubber washers on both sides of the body. I found a 2" radiator hose with a 45 degree bend at Advanced Auto Parts to connect the new flange to the tank. The chrome cap compliments my chrome tail strip nicely, I think.

[BQS4]

Nice one George, my idea was to get the filler cap off a 73 model or so Corvette, where you would have a flush fitting, body colored door, and flip it open, and your cap (you could use a more available locking type) would be right there. Some might dress up the door with the chrome blitz emblem like the Corvettes have their crossed flags emblem on it.

[opelenvy]

Say it ain't so Gene! Make the GT more like the Vette!? Nooooo!
No, seriously, that would be cool too.
More pictures of my mod in my gallery.

[Phoenix]

I think that you did a great job. It's something that I'd like to do to one of my GTs. Thanks for all the pics and I think the best part is that you can return it stock anytime you want or put it on another car.

[neuropel]

Keep an eye on that radiator hose since it's likely not fuel-grade. If you check a Napa and other places, you can find a piece of fuel hose that will do the job for you (though it's likely to be pretty pricey).

Best to be safe and use the right materials!

Todd

[oldopelguy]

Originally Posted by neuropel Keep an eye on that radiator hose since it's likely not fuel-grade. If you check a Napa and other places, you can find a piece of fuel hose that will do the job for you (though it's likely to be pretty pricey). Best to be safe and use the right materials! Todd

What he said, though the easiest, quickest, and cheapest place to find proper sized, fuel rated, large diameter fill tubing is your local marina or boating supply house. Pretty much every boat over 10' has a built in tank these days, and has to have some tubing run to it from the fill connection.

[markandson]

What about venting? Shouldn't there be something similar to the original setup up at the neck? On a fast fill the air in the tank has to have some place to go. Or is that what I see next to the filler?

[opelenvy]

Originally Posted by oldopelguy What he said, though the easiest, quickest, and cheapest place to find proper sized, fuel rated, large diameter fill tubing is your local marina or boating supply house. Pretty much every boat over 10' has a built in tank these days, and has to have some tubing run to it from the fill connection.

I went to a rubber and gasket house and the only fuel rated 2" ID hose they had was wire wound and VERY stiff. It would put major pressure on the flange/cap/body after making that 45 degree bend in only 9" of length. I mentioned to him about radiator hose and he said that it is for the most part, the same grade as the fuel hose. Finding 2" ID fuel hose is tough. I tried Tractor Supply and auto parts stores. Didn't think about marine application though. I am right in the middle of three big lakes so that shouldn't be hard to find. Thanks for the idea.

[officertyo]

hmmm??? i wonder if i could do the same to my wagon?

[raisinracer]

Instead of trying to bend the hose make the offset out of metal tubing and just join the ends with the fuel rated hose. You can get U-bends in the right size and for tighter bends use what is called a donut, just a tighter style of a U-bend.

[BQS4]

Originally Posted by opelenvy Say it ain't so Gene! Make the GT more like the Vette!? Nooooo! No, seriously, that would be cool too. More pictures of my mod in my gallery.

George;
Believe it or not, the ideas was not to make it look more Vette like, but, like you wanted, to elminate the "wind-up" look with something that was very subtle, but, functional. It just happens to be on Vettes

[opelenvy]

Originally Posted by markandson What about venting? Shouldn't there be something similar to the original setup up at the neck? On a fast fill the air in the tank has to have some place to go. Or is that what I see next to the filler?

There is a vent on the tank. I believe it is actually for the return line from the fuel filter. But the cap is vented as well.

[opelenvy]

Originally Posted by raisinracer Instead of trying to bend the hose make the offset out of metal tubing and just join the ends with the fuel rated hose. You can get U-bends in the right size and for tighter bends use what is called a donut, just a tighter style of a U-bend.

Yes, I had thought about doing this. Worst case, I could take it back off and weld a 45 on there and use the original rubber.

[soybean]

Beautiful job George. That is really nice looking and compliments the car too. Nice documentation on the install as well. Jarrell

[wrangler]

I noticed that you said you got your 2.5 - 2 inch reducer at O'Rielly's. They do carry 2" fuel rated hose for filler applications (whether the Nacdoches of Lufkin stores has it in stock may be another question). It is alot more expensive than radiator hose ($21.99/ft here in FL) but worth the peace of mind of knowing that your hose wont deteriorate and leave trash in your tank.
Gasoline and it's vapors can deteriorate the type of rubber used in radiator hose, and though it might take a while to cause harm, it might be best to take care of it up front.
JMTCW
Brett

[RallyBob]

On page ten of this pdf: Fuel Safe Accessories , you'll see there is 2", 2.25", 2.5", and 3" filler hose available. I checked at a local speed shop and the 2.25" and 2.5" runs about $5-$6.5 per foot.

Bob

[opelbits]

As an alternative, the Triumph Spitfire pop-open fuel cap/fillers will work nicely, too. Same filler neck diameter as the Opels and, if I remember right, it also uses a rubber grommet to position it in the hole.

[opelenvy]

Originally Posted by RallyBob On page ten of this pdf: Fuel Safe Accessories , you'll see there is 2", 2.25", 2.5", and 3" filler hose available. I checked at a local speed shop and the 2.25" and 2.5" runs about $5-$6.5 per foot. Bob

Hmm. They have one that looks just like mine.
Thanks Bob. I like $6.50/ft better than $$22.00/ft.

[jtb]

Originally Posted by opelenvy I researched several different options and ended up with the motorcycle cap.

Looks great! I've seen another like this, but it was larger (on Jon Haas' car?)

Can you tell me more specifics on the cap? What is the original application?

Thanks,

jtb

[opelenvy]

Originally Posted by jtb Looks great! I've seen another like this, but it was larger (on Jon Haas' car?) Can you tell me more specifics on the cap? What is the original application? Thanks, jtb

Thank you for your compliments.
Originally intended for a Harley Davidson! It comes in one and two for the two tank HD's. Vented and non-vented, locking and non locking. It is chromed instead of polished aluminum Which I love the polished aluminum look, but my tail strip and bumpers are chrome so it matches the car better than the aluminum would. The mounting screws that came with it are too short so I had to buy some stainless steel ones that are about twice as long at a local hardware store for $0.30/ea. The nylar lock nuts were also $0.30/ea. I thought about just drilling and threading the flange but I don't have a drill press and getting it perfect would have been tough. With the nuts I had to reach inside the tail light with a wrench to hold the nuts.
The OD of the whole thing is about 3.6"
The link to the place is V-Twin Manufacturing® - Aftermarket Products for Harley Davidson and Antique Motorcycle Parts
They sent me a catalog on CD as well as a paper catalog about as big as a Dallas phone book. The cap was around $67. I got it as a Christmas present so I don't know exactly.
It came with one gasket and I had to buy a set of 5 more just to get one for the bottom side. It was like $15 for those 5 gaskets, kinda steep. So I have 4 more. The 2.5" to 2" reducer was $2.99 at O'Reilly Auto Parts. I had a local welder make the flange and weld it to the reducer for $20. What can I say, it's cheaper in the country.