Replacing Fuel Vent

ryanc2 · Jun 3, 2009

I've read through many of the project posts regarding fuel vents and was looking to replace my old style plastic cap on my '99 2100 with the new version. Emailed Robin for the part number and she did confirm that the hole would be a tad larger.

http://www.gemlux.com/catalog.aspx?page ... s&item=954

One thing not outlined in the project posts was how you guys actually went about enlarging the hole. Any details about the process and difficulty would be appreciated.

Thanks in advance...

DaleH · Jun 3, 2009

ryanc2":33vqy5cv said:
One thing not outlined in the project posts was how you guys actually went about enlarging the hole. Any details about the process and difficulty would be appreciated.

Find piece of wood ~1" thick, even if you need to cut one out using a hole saw. Once you have it, slip it over the drill bit for the proper sized hole saw you need. It serves as a "pilot" to help center the new holesaw until the teeth are cutting in their own kerf. I put a drill stop onto the bit to prevent the plug from being pushed to the bottom of the bigger hole saw, but you could use a short length of suitable dowel.

Tape off area with 3M blue tape. To minimize chipping the gelcoat, put drill in reverse and SLOWLY (low, low RPMs) spin the bit backwards to wear a shallow groove into the glass. Tough on the tools, but better than splitting or chipping hard gelcoat. Then reverse direction and have it, again, watch your speed and feed.

See sketch below ...

Porkchunker · Jun 3, 2009

I took a dremel tool with a sanding drum and just kept going around and around the inside of the old hole until I got a press-fit of the new vent. Calibrated eyeball helps.

Dave

aka

Megabyte · Jun 3, 2009

Rat-tail file.

Parkerman · Jun 3, 2009

Burtona · Jun 4, 2009

Porkchunker":3ryxd7gg said:
I took a dremel tool with a sanding drum and just kept going around and around the inside of the old hole until I got a press-fit of the new vent. Calibrated eyeball helps.

Dave

aka

Me too. I got one of the flush vents (forgot who makes it) and the flange was plenty big to not have to worry about a perfectly round hole.