Boat Deck Gas Cap
- Thread starter muskokamarc
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scoflaw
Well-Known Member
- Aug 10, 2011
- 6,395
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- 1999 Powerquest legend 260 sx 502 mag
2005 Baja 242 islander 496
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- 502 mpi Bravo 1
496 mag B1
Fill old holes and drill new holes
muskokamarc
Member
Is that really the only option if I want to put a new one in?
If I do that, what do I fill the old holes with and how should I drill new holes? Don't want to ruin anything
- Apr 26, 2009
- 5,821
- Boat Info
- '97 330 Sundancer, Raymarine C80 suite with radar, Mercury 310 Hypalon w/8hp Yammie 2stk
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- 2X 454 carbs w/ vDrives
If its just the cap you lost, you will be able to find the right one. You just need to figure out what one to buy. Our marina has a bunch of different sizes in stock at all times. I think its because the kids that pump the gas drop them in the water pretty frequently.
Those chains break all the time. Mine was gone when I bought my boat and same for my last boat.
muskokamarc
Member
Yea I figure I could just buy the cap instead of the whole unit with the screws. I'm nervous to try and take the little broken end out of the gas throat as it would probably fall down into the tank...
I always fear the chain breaking when the cap is just hanging. I just removed the chain and stow the cap in a safe spot when fueling.
If I were you I would just get a new cap and not mess with the existing unit. It seems to look in good shape.
The one you have looks pretty "generic". I'd hazard that you won't find an exact match for a 1985 model boat. It looks like yours is 3 1/8" or so; most of the ones I've seen are 3" so are a bit smaller. Gas fills are usually sized for 1 1/2" hose.
You could try searay-part.com for a match. Perko has a variety of styles, some of which have 3 1/8" flanges or larger. Try looking at their site then googling the part number.
If you need to fill holes try using some epoxy putty. It comes in several colors like grey and white. Tape around the hole, knead the putty, and press into the hole and smooth out. If the new deck fill covers the area you're done. If not you'll need to try to match the gel coat with a repair kit where you mix up matching color. First remove a bit of the epoxy so you have space for the gel coat.
To drill holes: First put masking tape over the area. Mark the holes, then drill small holes on the marks through the gel coat. If you have a counter sink bit use that to go through the gel coat so the proper size bit doesn't chip and crack it.
Next, I always use the over drill and fill with epoxy approach for any through-deck hole. Drill a hole that's slight over sized (1 or 2 drill bit diameters larger). Fill with your choice of epoxy - again the putty type is excellent for this use. Let it set up then drill the proper size hole for your fastener. This ensures that there is a leak, the screw hole is sealed and water will not penetrate the deck. You can also line the larger diameter hole for the deck fill with epoxy for the same purpose.
You could try searay-part.com for a match. Perko has a variety of styles, some of which have 3 1/8" flanges or larger. Try looking at their site then googling the part number.
If you need to fill holes try using some epoxy putty. It comes in several colors like grey and white. Tape around the hole, knead the putty, and press into the hole and smooth out. If the new deck fill covers the area you're done. If not you'll need to try to match the gel coat with a repair kit where you mix up matching color. First remove a bit of the epoxy so you have space for the gel coat.
To drill holes: First put masking tape over the area. Mark the holes, then drill small holes on the marks through the gel coat. If you have a counter sink bit use that to go through the gel coat so the proper size bit doesn't chip and crack it.
Next, I always use the over drill and fill with epoxy approach for any through-deck hole. Drill a hole that's slight over sized (1 or 2 drill bit diameters larger). Fill with your choice of epoxy - again the putty type is excellent for this use. Let it set up then drill the proper size hole for your fastener. This ensures that there is a leak, the screw hole is sealed and water will not penetrate the deck. You can also line the larger diameter hole for the deck fill with epoxy for the same purpose.
The caps can be a pain the rear to match. Good luck.
If you want to remove the chain try getting a pair of locking forceps. Use the to grip the stub of the chain so it doesn't fall into the tank. Can find them in HW stores, harbor freight, etc. I have a couple sets; they are incredibly handy for all kinds of things.
sbw1
Well-Known Member
- Oct 10, 2006
- 8,189
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- Apr 26, 2009
- 5,821
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- '97 330 Sundancer, Raymarine C80 suite with radar, Mercury 310 Hypalon w/8hp Yammie 2stk
- Engines
- 2X 454 carbs w/ vDrives
IMO you are better off without the chain. For the reason Andy k says. Eventually the chain WILL break and when it does, the odds of the cap falling in the water is pretty high and then you are without a cap. Just find one that fits and then buy 2!
sbw1
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- Oct 10, 2006
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Getaway
Well-Known Member
- Oct 13, 2010
- 1,077
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- 1998 290DA Sundancer
Lowrance electronics, Fishhawk, Scotty Downriggers
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When one breaks off, take the one off your water fill inlet and use that one for your gas cap until you can locate a new one. Experience.....
You can get one that is really close from West Marine. I bought that one and wire wheeled the threads until it screwed into the fill hole on my '88 268DA. The one from West Marine has a slightly larger thread pitch diameter that keeps it from threading all the way down tight. A polish job was all it needed to seat tight against the oring.
Good luck!
You can get one that is really close from West Marine. I bought that one and wire wheeled the threads until it screwed into the fill hole on my '88 268DA. The one from West Marine has a slightly larger thread pitch diameter that keeps it from threading all the way down tight. A polish job was all it needed to seat tight against the oring.
Good luck!
