Steve Cragg Posted January 23, 2010 Share Posted January 23, 2010 I am in the process of fitting an aero filler cap. There is a small peg on the back of the outer flange that holds the cap retainng wire. When I offer the flange up it is clashing with the rim of the filler neck. It looks like the cap is designed to fit into a neck with a deeper recess. The only way I can see round it is to either to remove the peg (and hence the retaining wire) or drill a hole in the neck where it clashes so it fits. Has anyone else had this problem? Any help greatly appreciated Steve Superlight #63 Link to comment Share on other sites More sharing options...
Mark w Posted January 23, 2010 Share Posted January 23, 2010 Mine doesnt have a peg , sounds like you have a newer version . If you drill a hole in the filler neck do you not run the risk of fuel spilling into the boot area ? I would cut the peg off , your unlikely to forget to refit the cap and anyway it sounds like it will hang down and possibly scratch the paintwork Link to comment Share on other sites More sharing options...
Steve Cragg Posted January 23, 2010 Author Share Posted January 23, 2010 Thanks Mark. Fuel wouldn't spill out as I would only be drilling the rolled edge of the top of the filler neck which is all contained within the neck itself. I haven't seen any reports of similar problems so wondered whether it was a new feature. The peg is only about 3mm dia so not a big deal to drill out. Is there no retaining wire on yours? I did have similar thoughts about the cap scratching the car as it would definitely be resting on the back panel when undone. I'll see if anyone else has come across the problem before I butcher either the cap or the car Steve Superlight #63 Link to comment Share on other sites More sharing options...
CageyH Posted January 23, 2010 Share Posted January 23, 2010 Mine does not have a retaining wire either. Only dead fish go with the flow....! Link to comment Share on other sites More sharing options...
Support Team c7trp Posted January 23, 2010 Support Team Share Posted January 23, 2010 Hi Steve, I've just done this on an 03 car, and to get the cap to fit properly I had to remove the "internal flange" from the filler neck...the bit that located the metro style filler cap. Otherwise, when you fit it all together, not only does the pin foul, but you can't get cap in either ☹️ Removed by chain drilling and filing, but if you've got a dremmel or die grinder it would be easier Oh, BTW the larger cut out in the outer ring goes at the top to give room for the filler nozzle..... Link to comment Share on other sites More sharing options...
Steve Cragg Posted January 23, 2010 Author Share Posted January 23, 2010 Thanks Tim, Glad its not me going daft. Hadn't got to the stage of finding that the cap itself wouldn't fit - sounds like there is a bit of a design issue don't you think. Still what should you expect for £100 🙆🏻 Having said that they still look the dogs compared to the plastic metro cap 😬 Steve Superlight #63 Link to comment Share on other sites More sharing options...
Racing Snake Posted January 24, 2010 Share Posted January 24, 2010 If you upgrade the fuel cap does the filler pipe need to be upgraded too ? Mad Hatter Racing - Feel The Duralight R Torque 😬 Carl Van Baars Link to comment Share on other sites More sharing options...
6speedmanual Posted January 24, 2010 Share Posted January 24, 2010 The Rover Metro cap is lighter.... Peter BRAWNGP green SUPERLIGHT FCITW 2009 😬 Link to comment Share on other sites More sharing options...
Steve Cragg Posted January 24, 2010 Author Share Posted January 24, 2010 I've never seen reference to an upgraded filler pipe to go with the aero cap and I would have thought Catreham would mention it when people are buying the aero cap. I've spent a couple of hours today drilling out the rolled lip as suggested by Tim. Looks a right mess at the moment but at least it fits now. .....and Peter you are right. There is a big difference in weight between the plastic cap and the aero. So this is definitely not a performance upgrade Steve Superlight #63 Link to comment Share on other sites More sharing options...
Support Team c7trp Posted January 24, 2010 Support Team Share Posted January 24, 2010 I used a half round file and finished it off with one of these before repainting... Link to comment Share on other sites More sharing options...
Willie. Posted January 24, 2010 Share Posted January 24, 2010 Can any of you guys confirm the following: 1) Does the old aluminium flange rivetted to the back panel with 6 rivets, to which the filler neck is screwed, come off (i.e. you need to drill the rivets out)? 2) If yes...do the 6 holes in the new filler cap line up with the old rivet holes? Thanks, Willie Link to comment Share on other sites More sharing options...
Steve Cragg Posted January 25, 2010 Author Share Posted January 25, 2010 1) Yes it does. You start by undoing the two self tappers that hold the filler neck to the ally flange and then drill out the rivets 2) No the holes don't line up. You need to drill new 6mm holes. The aero cap does cover the old holes. Steve Superlight #63 Link to comment Share on other sites More sharing options...
Willie. Posted January 25, 2010 Share Posted January 25, 2010 Steve, Thanks. Exactly what I was after. Not what I wanted to hear...but needed to know. Thanks. Willie Link to comment Share on other sites More sharing options...
Steve Cragg Posted January 25, 2010 Author Share Posted January 25, 2010 Willie, My guess is that the reason for the holes not lining up and the cap not fitting etc is that this is a standard item that has had Caterham badging added. Might be wrong but if I am then someone has made a real mess of designing it Steve Superlight #63 Link to comment Share on other sites More sharing options...
Racing Snake Posted February 15, 2010 Share Posted February 15, 2010 Just completed the task What muppet designed that ? Ok i removed the inner flange of the filler neck with a small cutting wheel on a dremmel then cleaned it up with a grinding wheel.Then re drilled the 6mm mounting holes Retaining wire is being kept for the moment but first sign of marking my paintwork and its history. Caterham Cars - dont tell me you guys cant get this designed/spec for this product correct so it is a straight swap Mad Hatter Racing - Feel The Duralight R Torque 😬 Carl Edited by - Mad Hatter on 15 Feb 2010 09:26:27 Link to comment Share on other sites More sharing options...
tiddy1 Posted February 15, 2010 Share Posted February 15, 2010 I just fitted mine at the weekend, yes I had to grind out the inner part of the filler neck but the holes in the alloy spacer lined up with the captive nuts in the filler neck , drilled 6 more holes in the rear panel and fits no problems. one question though does the cork washer go on the inside or outside of teh rear panel? Simon Link to comment Share on other sites More sharing options...
Racing Snake Posted February 15, 2010 Share Posted February 15, 2010 Simon i would say inside as the cap has an o ring Mad Hatter Racing - Feel The Duralight R Torque 😬 Carl Link to comment Share on other sites More sharing options...
Steve Cragg Posted February 15, 2010 Author Share Posted February 15, 2010 Yeah I fitted mine inside. As Carl says the O rings will seal the external cap assembly. Finished mine off yesterday. Spent a fair while grinding out what was left of the inner flange and then used a medium emery paper to get it nice and smooth. Painted up with smooth Hamerite and unless you look closely you can't tell it has been butchered. I still think this is a standard design that has been badged up with the Caterham logo. If not whoever designed it needs sacking 🙆🏻 At the very least there should be a health warning on the work required to fit. Having said that now that its all finished it does look the dogs and it was worth the hassle Steve Superlight #63 Link to comment Share on other sites More sharing options...
tiddy1 Posted February 15, 2010 Share Posted February 15, 2010 Thats what I thought, Steve, be aware that hamerite dissolves in petrol, so I doubt it will stay on for long! Simon Link to comment Share on other sites More sharing options...
Support Team c7trp Posted February 15, 2010 Support Team Share Posted February 15, 2010 I think Hammerite will be OK assuming it has fully cured... Nicked from the datasheet: "It is based on synthetic resins, fast drying solvents and when fully cured resists all common building materials and splashing by dilute acids/alkalis, petrol and diesel." Could be wrong, but its been OK for me in the past Expect biggest problem will be chipping from the petrol pump nozzle. Link to comment Share on other sites More sharing options...
tiddy1 Posted February 16, 2010 Share Posted February 16, 2010 I cleaned 2 year old hamerite off wishbones with petrol ! Simon Link to comment Share on other sites More sharing options...
john milner Posted February 16, 2010 Share Posted February 16, 2010 Is there a good looking cap on the market that doesn't need chopping about? The standard item is not pretty but I'm not going to change it if it means the risk of getting metal filings in the tank. Link to comment Share on other sites More sharing options...
Racing Snake Posted February 16, 2010 Share Posted February 16, 2010 No chance of getting any swarf in your tank as you have to remove the filler neck anyway. Its not that difficult and well worth the hassle. You can always remove the wire that retains the cap and pin, that would make it easier. Mad Hatter Racing - Feel The Duralight R Torque 😬 Carl Link to comment Share on other sites More sharing options...
Steve Cragg Posted February 17, 2010 Author Share Posted February 17, 2010 I didn't remove the filler neck. I put two pieces of paper towel down the filler neck and used a vacuum as I removed them to catch any stray pieces of swarf. The flap in the neck is a final barrier to stuff getting in the tank. Steve Superlight #63 Link to comment Share on other sites More sharing options...
Racing Snake Posted February 17, 2010 Share Posted February 17, 2010 Removed the flapper in the neck as its a total pain and excess weight 😬 Mad Hatter Racing - Feel The Duralight R Torque 😬 Carl Link to comment Share on other sites More sharing options...
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