Boxerworks.com

I picked up a couple early /5 aluminum gas caps on ebay recently, both could use a new gasket. I see the gaskets and rivets are available, but it's not real obvious how to go about replacing them. Anyone done this job or have any tips or tricks to ensure success? Drill out old one, beat in new one?

Duane says this on his site:

"The cap has a gasket under it to seal fuel. A rivet is pressed into the cap to hold the parts in. It is hard to remove. Some gently grind flats on the sides so that pliers can get a good hold on it and rotate while pulling it out. Some owners tap the hole and install a screw. That makes it easy to repair in the future. I suggest using Locktite on that screw. If it falls into the tank, it is hard to remove again."

Kurt in S.A.

Danke! "If it falls into the tank, it is hard to remove again." Am I the only one thinking "magnet on a stick"?

Tim Shepherd wrote:Danke! "If it falls into the tank, it is hard to remove again." Am I the only one thinking "magnet on a stick"?

Not the screw, screwball: THE CAP!

Major Softie wrote:

Tim Shepherd wrote:Danke! "If it falls into the tank, it is hard to remove again." Am I the only one thinking "magnet on a stick"?

Not the screw, screwball: THE CAP!

Dang!

Yep I used a 8-32 brass screw with blue loctite when Red was a stock R75/5 I used leather for the gasket

the days of stock and orginal are gone........................

I've done a couple of these and I reckon that tapping the case for a small screw gives a better than original result:



Once you've pulled out the rivet (or "notched nail" as I think it's called) I wouldn't want to drive another back in - a surprisingly crude method of attachment...