Petrol filler cap replacement

[Mutley00]

Just wondering how to transfer the 'internals'/seal from the old cap to the new one.

It would appear I have to file or grind off the 4 lugs holding the seal in place to remove it, but how do I secure it to the new cap? Is the metal of the 4 lugs soft enough to hit with a hammer so it spreads to secure the seal or the other option I considered, was drilling out a hole in the centre of the 4 lugs and using self tapping screws to secure the seal.

I presume the two pins that secure the hinge and the catch just push out?

All advice appreciated.

[v8s4me]

It looks like the method you've outlined but like you I'd be worried about tapping the new cap with a hammer.
Where did you get the new cap from? Did you get a new seal with it?

[mentall]

I filed the 'rivets' flat, drilled 'n' tapped holes and fitted elegant S/S socket head flanged screws (M5? M4?). I realised afterwards that I only needed to replace two of them with screws, but that would have looked cheap.

[Blue 30]

What I did on reassembly of my re chromed cap parts, was to place the cap on a soft duster, replace all of the innards (you'll need 3 hands or a helper to hold it all), put the washers back on their studs, then hit each stud in turn with a centre punch. This flares out the stud to lock the washer back in place. X4 times of course !
The hinge pins have a short straight spline on one end only. Knock them out the way they were knocked in, so that the spline isn't being knocked all the way through the hole.
T.

[Mutley00]

Thanks for your advice chaps - here goes! I didn't get a new seal with the cap Joe, but thanks for highlighting - it does look a bit past it. I'll try and find one from the usual suppliers.

[lordofthewings]

I sourced some rubber sheet of the correct thickness on Ebay (a small "sample" size will do) and used a circle cutter to produce the new gasket. Reassembled with the re-chromed parts. Nearly three years on it hasn't cracked and doesn't leak fumes.

[Mutley00]

Thanks for your advice chaps - all sorted now. Unfortunately the two visible parts of the neck and the latch couldn't be re-chromed as they are cast metal apparently, so I had to cover them with chrome gift wrap tape that does the job admirably. Also the seal was just a bit dirty and this stuff does a remarkable job of bringing tired rubber back to life especially door seal and windscreen surrounds.

https://www.ebay.co.uk/itm/1x75ml-W%C3%9CRTH-RUBBE...

Cheers