Chloe Zhang
Vented gas caps are a thing of the past, but you can still find them labelled as such in catalogues. Modern-day gas caps only allow air to enter the tank as fuel is used, with a valve that blocks fumes from escaping. This has led to pressure build-up in tanks, which can be remedied by drilling a hole in the valve. Alternatively, you can modify your ventless gas can by adding a vent. However, be cautious when using plastic caps as certain types of plastic can melt when exposed to fuel.
| Characteristics | Values |
|---|---|
| Hole Size | 1/16" |
| Drill Bit Size | 21/64", 9/64", 1/16" |
| Valve Type | Slime brand CH3 Tractor valves |
| Plastic Type | Thick, Resistant to fuel |
| Vent Type | One-way vent |
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What You'll Learn
Choose the right plastic for your gas cap
Choosing the right plastic for your gas cap is essential to ensure safety and functionality. Here are some factors to consider when selecting the appropriate plastic:
Material Selection
The material of the gas cap must be chemically resistant to the type of fuel it will encounter. Modern gas caps often use materials like neoprene or polyurethane, which offer better resistance to ensure a tight seal. It is worth noting that gasoline will eventually break down most plastics, especially with today's ethanol-blended gas, so choosing a plastic with suitable chemical resistance is crucial.
Size and Fit
The size of the gas cap must correspond to the filler neck size of your vehicle. An ill-fitting cap can cause issues, as it may fall off or not work at all. Ensure that the inner diameter of the cap is slightly larger than the outer diameter of the filler neck. This ensures a secure fit and helps prevent leaks.
Colour Coding
The colour of a gas cap is not just for aesthetics. Different colours often indicate the type of fuel the vehicle uses. For example, black fuel caps are typically for gasoline with less than 10% ethanol content, while green fuel caps indicate diesel fuel. Yellow fuel caps signify flexible fuel vehicles that can use gasoline with 15% to 85% ethanol content. Colour-coding helps identify the correct fuel type and prevents misfuelling.
Ventilation
A gas cap with proper ventilation is crucial for safety. Some gas caps have a "slow-release" feature, allowing vapours to escape slowly and preventing a sudden release of pressure. This feature is important to avoid a dangerous build-up of fumes, which can be explosive in sufficient concentrations.
Durability and Compatibility
Consider the durability and compatibility of the plastic gas cap with your vehicle's fuel system. The plastic should be able to withstand the chemicals in the fuel and the environmental conditions it will be exposed to. Additionally, ensure that the gas cap is compatible with your vehicle's specific make and model, as filler neck sizes can vary.
By considering these factors and consulting reliable sources or professionals, you can choose the right plastic for your gas cap, ensuring safety, functionality, and compatibility with your vehicle's fuel system.
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Drill a hole in the cap
Drilling a hole in a plastic gas cap is a simple and quick process, but it should be approached with caution. The first step is to ensure the gas container is empty and well-ventilated to prevent the ignition of fumes by sparks from the drill. Filling the container with water or another non-combustible fluid is another way to ensure safety.
The next step is to choose the correct drill bit. Forstner-type bits are recommended for a smooth and round hole, and a 1/2-inch bit is ideal for a tight fit. A 1/8-inch NPT tap, which requires a 5/16 drill bit, and a small 1/16-inch drill bit can also be used. It is important to note that round bits will not make a round hole, so paddle bits are preferable.
When drilling, it is crucial to centre punch the top centre of the cap to prevent the drill bit from wandering. Drilling slowly and carefully is essential, and it is recommended to start with a smaller pilot hole before increasing the size. This process should only take around 10 minutes, and the result will be a vented gas cap that resists oil or gas splashing out.
To finish, the vent should be pounded into the hole with a rubber mallet, ensuring a tight and leak-proof fit. It is important to clean up any plastic shavings that may have fallen into the container during the drilling process.
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Use a drill bit to thread the valve into the plastic
Drilling a hole in the plastic gas cap is a straightforward method of venting it. This can be done with a standard drill and drill bit. However, it is important to note that the size of the drill bit will depend on the type of valve you intend to use.
For example, if you are using a 1/8" NPT tap, you will need a 5/16 drill bit, as well as a smaller 1/16" drill bit. Begin by centering the punch on the top center of the cap so that your drill bit does not wander, and then drill straight through with the 1/16" drill bit. This is best done with a drill press. Next, flip the cap over and use the 5/16 drill bit to drill deep enough for the fitting, allowing a bit of extra room so you can tap deep enough without drilling all the way through the cap.
If you are using a different type of valve, ensure that you have the correct size of drill bit to create a hole that is slightly smaller than the valve stem. This will ensure a tight fit when you thread the valve into the plastic. It is also important to remember to remove the valve core before threading it into the plastic.
Additionally, consider using a cutting fluid to make the process easier, and always take the necessary precautions when operating power tools, such as wearing eye protection and working in a well-ventilated area.
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Drill out the inside of the valve
Drilling out the inside of the valve is a crucial step in venting a plastic gas cap. This process involves removing the internal valve mechanism to create space for air to flow in and out of the gas cap. Here's a detailed guide on how to approach this task:
Tools and Materials
First, gather the required tools and materials. For this specific step, you'll need a drill and specific drill bits. The drill bit size can vary depending on the valve type and the desired airflow. A common recommendation is to use a 9/64" drill bit to enlarge the inside of the valve and allow for better airflow. Additionally, you'll need to wear appropriate safety gear, including eye protection and gloves, to ensure a safe drilling process.
Removing the Valve
Before drilling, you must remove the actual valve from inside the gas cap. This step ensures that you have clear access to the inside of the valve mechanism. Carefully disassemble the gas cap to extract the valve, making sure not to damage any other components. Place the valve in a vice or a secure holder to keep it steady during the drilling process.
Drilling the Valve
With the valve securely held, start the drilling process. Carefully insert the selected drill bit (in this case, the 9/64" bit) into the drill and position it at the opening of the valve. Begin drilling slowly and with controlled pressure to enlarge the interior of the valve. Take your time and ensure that you don't apply excessive force, as this can damage the valve or the drill bit. Continue drilling until you achieve the desired diameter and smoothness inside the valve.
Deburring and Cleaning
Once you've finished drilling, carefully remove any metal shavings or debris from the valve. Use a small brush or compressed air to clean out the valve interior thoroughly. You can also use a cutting fluid to help remove any remaining debris and create a smooth finish. It's crucial to ensure that the valve is entirely clear of any obstructions that might hinder airflow.
Reassembling the Gas Cap
After drilling and cleaning the valve, it's time to reassemble the gas cap. Carefully insert the modified valve back into the gas cap, ensuring it sits securely in place. Check that the valve aligns correctly with the vent hole drilled in the gas cap. This step ensures that the airflow moves through the intended path. Once you've confirmed the proper alignment, secure the valve in place according to the gas cap's design.
Testing and Verification
Finally, test the vented gas cap to ensure it functions correctly. This involves checking for proper airflow and verifying that the cap vents excess pressure without causing fuel spillage. You can perform this test by attaching the gas cap to its corresponding tank and observing any changes in pressure or airflow. Ensure that the vented gas cap complies with safety standards and regulations to prevent any hazards.
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Test the cap to ensure it is vented
To test if your gas cap is vented, you can try the following methods:
Check for a "VENTED" Stamp
Firstly, check if your gas cap has the word "VENTED" stamped on it. If it does, this is a good initial indication that your gas cap is vented.
Inspect for Holes
Inspect your gas cap for holes. A vented gas cap should have a small hole on the 'tank side' of the cap. If you see any holes blocked by another substance, such as Kreem, carefully scratch it away with a nail.
Listen for Gurgling Noises
Listen for gurgling noises when opening the petcock. If you hear gurgling, this could indicate that your gas cap is not venting properly, and the tank is not vented.
Observe for Vapors
If you have a vented gas cap, you may observe vapors escaping through the gas cap, which may result in a noticeable smell of gas.
The Sucking Test
As one user on CorvetteForum describes, the "unsanitary" test is to suck on the cap. You should be able to suck on the cap and feel air enter with some resistance. When you blow on it, you will meet more resistance before it vents.
The Flow Test
Another test is to turn on the petcock or ignition key to cycle the fuel pump. Observe the flow of fuel into the container. If it flows steadily, this indicates that your gas cap is functioning correctly. However, if it trickles and almost stops, it suggests a problem with the gas cap.
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Frequently asked questions
A vented gas cap is a cap with a hole in it that allows air to enter the tank as fuel is used.
Vented gas caps only allow air to enter the tank and a check valve stops air from exiting the tank, which can cause pressurisation issues.
You can drill a hole into the check valve to allow air to exit the tank.
A 1/16" drill bit is suitable for adding a vent to your gas cap.
Fuel has a tendency to melt certain types of plastic, so be careful when adding a vent to a plastic gas cap.
