Replacing Rubber Petrol Cap Holder

Vampyrebat

Member
Messages
3,117
The rubber degraded and snapped on mine a few months ago. I know this is a common fault with our cars (3200/4200/GS) as I have tried to get hold of another but they have all gone the same way. So I bought a sheet of 3mm rubber from Ebay (£5) and decided to fabricate my own.

73154

First you need to detach the rubber connecting tie from the plastic cap holder, this is done by pushing out 2 very small plastic locating pins (I didn't know this until I was about to drill it through and one popped out) and keep them safely to one side.

73155

Then I went about cutting out a new one using the old as a template (I made the girth twice as wide to make it stronger). Be very careful whilst drilling the small holes to fit into the plastic cap holder, this bit is a PITA and took me 3 attempts. The larger hole that locates the strap to the petrol flap is a walk in the park!! Also forgot to say before drilling all holes, run the holes over the drill bits to ensure you have the right size. I also had to file/sand down the end point that fits into the cap holder (both girth and thickness) as it is about 2 - 2.5mm.

73156

Finally, I sanded down all the rough edges to make it aesthetically pleasing on the eye and so it doesn't look like it has been hand-made (and because I'm OCD)!! pushed the plastic securing pins back into the cap holder with new rubber strap in-situ.

73161

End result..........Sorry the pics are a bit dark as my mobile camera flash is sh!t and I couldn't be arsed getting the car out of the garage as it was getting very close to Vino time!!

73162

73163
 

rs48635

Member
Messages
3,181
I just hang mine off the little hook. Maybe it is time to get the kit out and make my own strap on.
Is it by any chance a Fiat part? Am reminded of little shopping cars from past when opening the fuel cap.
 

MarkMas

Chief pedant
Messages
8,796
I just hang mine off the little hook. Maybe it is time to get the kit out and make my own strap on.
Is it by any chance a Fiat part? Am reminded of little shopping cars from past when opening the fuel cap.

Yes, I discovered the hook after about a year! But it would be nice to have a replacement for the rubber strap. (No, not like that!)
 

MarkMas

Chief pedant
Messages
8,796

Chimaera500

Member
Messages
189
Ha, yes, apart from that bit!! Have used my original Maserati blue cap. The outer plastic ring and rubber bit from the Fiat cap are the same, so just swapped this part over to my original cap. Apart from the diesel bit, and it being black, I think the actual caps are are the same part!.
 

Vampyrebat

Member
Messages
3,117
Mine had broken too, so I ordered one of the following caps for a fiat Panda! The whole cap is pretty much identical to the original. The complete outer ring with the rubber strap attached can be swapped over to your original Maserati cap. Part is identical.
https://www.ebay.co.uk/itm/Fiat-Bravo-Panda-Punto-Diesel-Fuel-Filler-Cap-With-Strap-Genuine/153959867665?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
If you can get them new then good result and would suggest moisturising them on a regular basis to prevent it perishing. I see the one you have in your link is already on the way out!! The rubber I ordered is more supple and with the added thickness should last forever and ever Amen!

If you other chaps are serious about ordering some replacements then I can see about getting a fabricator to copy mine and get a price for a job lot??!!
 

Gazcw

Member
Messages
7,700
I just hang mine off the little hook. Maybe it is time to get the kit out and make my own strap on.
Is it by any chance a Fiat part? Am reminded of little shopping cars from past when opening the fuel cap.
I think my Giulietta had the same.
 

rs48635

Member
Messages
3,181
I was keen to replace the rubber thingy at first. Now I only fill up when car has run a while with the light on. Adding about 80 litres of fuel allows me plenty of time, so quite unlikely I will forget anything. Often spot a few coins on the forecourt and plenty of tyre dust caps.
 

dgmx5

Member
Messages
1,142
@FIFTY , any chance of you getting these made? Otherwise I may but a new Fiat cap for ~£20 and simply swap over the strap.

Sorry, just realised that @Vampyrebat was considering a fabricator to make these.

Looking at the design (hole one end with two locating holes at the other), would this VW tether work:


83184
 
Last edited:

FIFTY

Member
Messages
3,100
@dgmx5 I got the Fiat cap and swapped the strap and O ring over to the blue Maserati cap

Would quite like the aluminium petrol cap but not overly keen on blowing nearly £200 on a new one - would be good to get one and have it copied like the gear knob - although they only fit the pre-face lift 4200, 3200 and some Ferrari's

831868318783188