other Petrol Fill-Up Solution (Project Write-Up)

[JeremyJames]

Hey friendlies. 

 

As we all know, the 2002 petrol fill-up situation is quite a bother and something I was personally tired of dealing with. My ruubber neck started cracking / tearing resulting in me having to go inside my trunk, unscrew it, fill up, and put it back on every time.. 

 

This afternoon I had some hours and decided to tackle the project. 

 

PARTS:

The gas tank neck diameter is exactly 2.1" od. 

I ordered a non-vented, 2" gas cap with a neck at 3" tall from Coyote Supplies. Knowing there will be a rubber coupling acting as a spacer I wasn't too worried about the short height, figured cutting or buying more rubber would be easier than steel. 

 

A local plumbing store (without a storefront) threw me a rubber spacer from their scrap pile after explaining to them what I was doing. No storefront, no price 

 

2 hose clamps and I'm ready for the install. 

 

 

INSTALL:

Attach one hose clamp around the neck of the gas tank to act as a guide when cutting. Also, have a shopvac positioned to collect and prevent all the metal dust from falling into your tank. 

 

I got a non-vented cap because I wanted to drill and route my own vent to prevent the trunk smelling like gas. The original vent hose will do just fine. A 7/32 drill bit keeps it nice and snug. Inside the gas cap neck there was a ridge to rest the bit on so I could get a nice downward angle for the vent hose. 

 

Next simply slip the rubber coupling over the gas tank neck, clamp it down. Then the gas cap neck, clamp it down, and re-route the vent hose. 

 

 

 

Then reinstall the origional gas cap. 

 

 

A simple 2 hour fix for one big reoccurring problem 

 

My one concern would be if the fuel cause corrosion on the rubber. I might swap out the rubber coupling for a marine hose line. 

 

Thanks! 

One of the most functional mods i've done in a while.

 

Best, 

Jeremy 

 

 

 

 

 

[Doug Riparetti]

Nice, do you have a # for Coyote Supplies?

 

Thanks,

 

Doug

[JeremyJames]

Hey Doug, 

 

Here is their website:

http://www.coyote-gear.com/

 

there are several options. I like the red cap, I might purchase that as well. Any will work assuming the od is 2"

 

thanks, 

Jeremy

[Doug Riparetti]

Thanks Jeremy

[pkchopp]

I did almost the same thing. Cut the filler squair, used Marine gas line and a Triumph TR6 gas cap with vent line. Took the plastic canister that sits under the passanger side of the package tray and filled it up with charcoal from the aquarium shop, ran my vent line to that.  Recently bought a new gas cap seal from Moss Motors and no more gas smell in trunk.  The best part is the ease in pumping gas straight down!

[JeremyJames]

yes! well done pkchopp. I looked at these, but couldn't resist the $18.00 compared to $118.00. haha.

An upgrade eventually though for sure. 

 

 TR6 gas cap with vent line. 

[LJtii]

Look below in the forum for the subject "California Gas Pumps." In it, you will find a post by Chris, who sells adapters. I bought one and have been using it with a smile on my face ever since. It's worth the small investment.

[M3M3]

Never been a fan of the in trunk fuel fill. fills the trunk with nice explosive gas fumes at every full up.

[pkchopp]

Never been a fan of the in trunk fuel fill. fills the trunk with nice explosive gas fumes at every full up.

Been doing this for over 20 years. NOT a fan of gas all over my paint!

['76mintgrün'02]

Speaking of gas on paint... I was filling my car at an old-school (ethanol-free) pump today and apparently somebody thought it would be smart to put the handle back in the pump with it locked on; so when I went to fill up, gas came out as soon as the attendant turned it on.  I was SO happy it was so close to the filler when it happened.  Within one second I thought, "this doesn't feel right.  Oh sh!t.  Whew!"  

 

(I will be checking that little detail for the rest of my life).

[Mike Self]

A caveat for Jeremy and those who have made this modification:  Make sure you secure the original gas cap so that it can't be removed--either bolt it in place or use a locking cap.  That way someone who isn't familiary with your mod wont' try to fill the gas tank via the original cap.

 

A friend and I learned this the hard way while refueling another friend's race car during a one hour CCA enduro with a mandatory pit stop at Mid Ohio.  The owner/builder/driver negelected to tell us that he had a fuel cell filled via a filler inside the trunk; the cap was a dummy.  My friend Mike managed to get a half gallon of gas from the dump can directly into the trunk, where it started dripping on the hot exhaust.  

 

I was on extinguisher duty; by some miracle that half gallon dripped on the exhaust and then onto the ground without catching fire.  We dope-slapped the car's owner/driver for not telling us about this mod, and made him promise to bolt the old cap in place to prevent another "situation."

 

Just a warning...remember Murphy's Law!

 

mike

[cda951]

Nice one, Jeremy, that looks clean.

It is a good idea to let the trunk air out after you fill up. Leave the lid open while you check tire pressures, fluids, etc.

I just hacked up an E30 filler neck that I got from a friend.

10 minutes of work with a hacksaw and cutoff wheel and a rubber filler neck sleeve from a Porsche 911. I just tried it and it works great.

I will need to find a gasoline-proof container to keep it in while in the trunk so there are no fumes.

Edited April 23, 2014 by cda951

[JeremyJames]

yes, In response to Mike. 

 

I will be the only one driving and fueling my 2002 haha. 

 

And a good way to render the gas cap useless is over tighten the gas cap, and loosen the center tension ring in the center of the cap. By doing this the gas cap will twist round and around forever, while never actually coming off. 

 

I found this out accidentally 

 

But thanks for the tip! 

[tups]

Before attempting this mod and hacksawing, grinding or drilling your filler neck, it bears mentioning that you should not have gas in your tank while doing this, or you might be in for an expensive and possibly lethal surprise.

 

On more or less the same note - gasoline vapours are much heavier than air - for you trunk-fillers -gas fumes in the trunk will not dissipate by leaving the trunk open for a few minutes.

[nicktahoe]

Did a very similar mod last weekend. Just got my car back from body, filled it up a few times, some fuel dripped down on the paint and that was the last time i was going to deal with that. Got a 2" piece of fuel hose from Napa and I'm using a non-vented aircraft fuel cap (http://www.aircraftspruce.com/catalog/appages/aeroscrewin.php).%C2'> and no more fuel on my fresh ass paint