Whats the best way to correct this?

[Beefer]

Had to replace the cpz fuel fill on my 84 SportCraft, as it was corroded and the plastic cap wouldn't screw in. I replaced it with a nice SS one, but the old one was 3.5" square, and the hole that the factory cut for it is huge. I can't find the same as the old one (don't really want it), and the one I got has the common 3"+/- diameter round flange. How do I install this so there are no gaps, etc. Right now, it's just 'there' in the hole from the old one.

 

[Mark42]

Re: Whats the best way to correct this?

Easy fix is to get a piece of Lexan between 3/8 and 1/2" thick in clear or white and cut an adapter big enough to cover the old mounting holes and "shadow" and with a 3" hole to fit the new filler neck. If the Lexan is clear, then paint it from behind with black, silver or some other contrasting or matching color. By painting the back of the "adapter", the paint won't
scratch off. Be sure the lexan is strong enough to handle having a gas pump handle in it and being leaned on.

Aluminum will work, but it does oxidize, and will need regular polishing to keep a shiny appearance.

Stainless steel plate will work too, but is hard to cut and rather expensive.

While in a department store, look at the white plastic cutting boards used in the Kitchen. That is a good and inexpensive source of some thick, tough plastic to make an adapter out of. And they are generally solid white.

Whatever material you use, be sure to seal it well with something like Boatlife or 3M 4200.

 

[Beefer]

Re: Whats the best way to correct this?

I like that idea. The boat is that tan color, so maybe some clear lexan painted like you said. Thanks Mark!

 

[Yacht Dr.]

Re: Whats the best way to correct this?

1/4" Stainless m8..stainless

Done .. done and when you give the boat to your kids..its will still be Done

Just my opinion...

YD.

 

[Beefer]

Re: Whats the best way to correct this?

A bit after I wrote this thread, I made contact with a restaurant equipment manufacturer in Orlando, and they make huge cutting boards and stuff. The woman I spoke with was super nice, and they sent me a piece of 1/2" scrap the size I needed for the cost of shipping. I didn't have a hole saw set, so the piece just sat there. Finally got around to going to Harbor Freight and got the hole saw kit.

Making the 4" outer circle took forever, and used all the power in the drill battery. The smaller/inner circle took about 30 seconds. Anyway, here's the finished product;

I think it looks pretty good.

 

[boatnut74]

Re: Whats the best way to correct this?

looks pretty slick, nice job.

 

[Mark42]

Re: Whats the best way to correct this?

Nice work. And it will last forever.

 

[gozierdt]

Re: Whats the best way to correct this?

Looks great! and the 1/2" thickness will be plenty strong when the gas hose is dragging on it