I have just bought a filler cap from Think Auto and tried to fit it yesterday, only to find that the filler neck on my tank (taken from my donor Corolla) is 43mm OD and the OD of the filler cap is 52mm. Does anyone have any suggestions as to how this can be sorted?

I am under the impression that the hose normally used is specially for fuel and therefore dont want to just make something fit that is lying around i.e. water hose.

I have emailed Think Auto for their advice/recommendations, but thought i would ask here as well, as there may well be a cheaper alternative, which i have overlooked.

As always, any help appreciated.

I had a similar problem. I just bought some suitable fuel hose to suit the smaller ID (from Europa IIRC), and it stretched fairly easily onto the larger ID fuel cap.

HTH Stu.

maybe 'big it up' with a few layers of duck tape, then jubilee it tight!

I think I would be a little concerned about using duck tape for a fuel filler application.

Doesn't petrol dissolve the adhesive on the tape?

Cheers

Mark

Yes it does. I would be more tempted to get some 43ID / 52OD tube, put this onto tank first then fit filler pipe. (ie make an adaptor).

Of course that size pipe is going to be nigh on impossible to get but 40ID (or similar) will stretch etc etc. Might be an idea though.

We have a local motor factors (very big one) that can do bespoke fuel pipes etc. They get them from a place called Linden Hose in Newton Aycliffe (Co. Durham) who can also make hydraulic pipes, up to the sizes used on commercial vehicles and JCB's. I dare bet most large places will have a supplier similar for pipe and tubes etc.

Another idea - can the tankl filler neck be modified? What about making an ali or stainless tube bent to desired angle and fitted with flexi pipe at each end (if space allows).

IHTH
Darren.

Thanks for the suggestions. I think the best way would be to scrap the original filler neck and make a new one the correct OD, or at least turn out a sleeve to slide over the existing filler and put a weld around it to seal it. In fact that is what i will do. Turn a sleeve with an ID of 43mm and an OD of 52mm.

Still need a cheap supplier of 52mm hose, approximately 6" long

Thanks again.

BTW if anyone has any alternative solutions please let me know as i wont get to the lathe until the weekend at the earliest.

If anyone does find a reasonable supplier, I need about 3" of 50mm ID Fuel Hose.

What about making a reducer? Any exhaust shop will have an exhaust shrinker/expander with which they could alter a short length of tube to suit the difference between the hose and filler neck.
You may even find a similar expansion on the end of an existing unused exhaust pipe.