Notices
928 Forum
Sponsored by:
Sponsored by: 928 Specialists

Metal Gas Cap Pawl Installed

 
Old 12-27-2009, 01:46 PM
  #46  
ammonman
Addict
Rennlist Member
 
ammonman's Avatar
 
Join Date: Jul 2008
Location: NW Arkansas
Posts: 2,030
Likes: 0
Received 0 Likes on 0 Posts
Default

No offense taken Paul. All totaled I had about 4-5 hours in getting my cap apart, fitting the new pawl, and re-assembling the cap. Last time I checked a new cap with key is about $150 plus shipping. A new cap keyed to your car via the VIN is around $300. As JP pointed out in his recent post, you could use a drill to cut the bulk of the material out and create the front rounded portion of the cavity. A steady hand could do it without a drill press and end up with something functional in less than an hour.. My goal was to end up with a working set-up using COMMON tools most of use have in the cabinet. As far as reproducing the plastic part accurately in steel, that is just my own type-A personality coming out. If I did not have JP's excellent blank to start with it would have taken significantly longer. Plus, now that I have the entire process of shaping the blank figured out I bet I could shave an hour or more off the total time.

As Jay said, a "time vampire", but a good learning experience in fundamental metal working. The modern lathes/mills/shapers just save time and increase precision. In the very old days it was all done by hand.

Mike
ammonman is offline  
Old 12-30-2009, 08:08 PM
  #47  
jpitman2
Addict
Rennlist Member
 
jpitman2's Avatar
 
Join Date: Dec 2002
Location: Australia
Posts: 4,689
Likes: 0
Received 0 Likes on 0 Posts
Default

Before we completel,y leave this, there is another way to make a pawl such its not under any spring loads. My first attempt was to make one without needing a spring to work. This requires a top cavity such that the pawl is retracted by the lock tumbler (normal rear wall thickness), but the front face is as close as possible to the tumbler cam, while still allowing the tumbler to turn properly. I found this meant the sharpish corners of the cam needed a little rounding to fit into the smaller cavity, and be able to just turn the 180degrees, and push the teeth out far enough to grip the white body of the cap. I still have one made in alloy I think. Anyway , we have a solution, and now a couple of people who can implement it as needed for those who dont have the skills or tools. For most of us, there will always be something that is beyond us, and we need help to accomplish. Thats why we are here to share things, IMHO.
jp 83 Euro S AT 52k, P110 Brian Long.
jpitman2 is offline  
Old 12-30-2009, 11:22 PM
  #48  
Alan
Electron Wrangler
Lifetime Rennlist
Member
Thread Starter
 
Alan's Avatar
 
Join Date: Mar 2002
Location: Phoenix AZ
Posts: 11,930
Likes: 0
Received 0 Likes on 0 Posts
Default

To get a new Porsche gas cap with matching key is an expensive option as just pointed out - even then all you have is a new stupid nylon pawl just waiting to fail... its a poor design in the materials that were chosen - in metal its an OK design...

Clearly this solution is quite a bit better than new... so is it worth it...?

I'm happy I did mine and still greatfull to JP (BTW I sent a few more of these out in the last few weeks).

As JP said - I also just drilled mine with a drill press and used a milling bit also in the press for fine tuning. No really elaborate tools were needed but electric hand tools are difficult to control so I prefer the press and hand files... obviously a dremmel can be used succesfully but its a little more challenging...

Alan
Alan is offline  
Old 12-30-2009, 11:24 PM
  #49  
jpitman2
Addict
Rennlist Member
 
jpitman2's Avatar
 
Join Date: Dec 2002
Location: Australia
Posts: 4,689
Likes: 0
Received 0 Likes on 0 Posts
Default

Alan, Maybe I will talk to tool makers again, and get another set done, while things are a bit slowish here. I am down under 5 spares now..
jp 83 Euro etc
jpitman2 is offline  
Old 03-22-2013, 04:11 PM
  #50  
Alan
Electron Wrangler
Lifetime Rennlist
Member
Thread Starter
 
Alan's Avatar
 
Join Date: Mar 2002
Location: Phoenix AZ
Posts: 11,930
Likes: 0
Received 0 Likes on 0 Posts
Default

BTW - I have plenty of blanks (from jp) availabe still... PM me if you need.

You do need to drill & finess a little - but its a "mostly there" starting point in mild steel.

Most of the difficulty to rekey a gas cap lock is getting the old barrel out (red part off the white part) - unless you order a totally new re-keyed one ($$$$).

For me putting a new (still crappy) one in wasn't worth it - it wasn't a money or time thing at all - I never want to have do this one again.

Alan

Last edited by Alan; 03-22-2013 at 06:27 PM.
Alan is offline  
Old 03-22-2013, 05:48 PM
  #51  
Mike B
Done With Sidepatch
Rennlist Member
 
Mike B's Avatar
 
Join Date: May 2001
Location: Calgary
Posts: 3,833
Likes: 0
Received 0 Likes on 0 Posts
Default

Alan...PM sent.
Mike B is offline  
Old 03-22-2013, 09:08 PM
  #52  
RFJ
Addict
Rennlist Member
 
RFJ's Avatar
 
Join Date: May 2010
Location: SW FL
Posts: 924
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by Alan View Post
BTW - I have plenty of blanks (from jp) availabe still... PM me if you need.

You do need to drill & finess a little - but its a "mostly there" starting point in mild steel.

Most of the difficulty to rekey a gas cap lock is getting the old barrel out (red part off the white part) - unless you order a totally new re-keyed one ($$$$).

For me putting a new (still crappy) one in wasn't worth it - it wasn't a money or time thing at all - I never want to have do this one again.

Alan
Alan,If I could get parts for two caps I would be very happy. Must cost something,no? thank you,Ray
RFJ is offline  
Old 03-22-2013, 10:38 PM
  #53  
Alan
Electron Wrangler
Lifetime Rennlist
Member
Thread Starter
 
Alan's Avatar
 
Join Date: Mar 2002
Location: Phoenix AZ
Posts: 11,930
Likes: 0
Received 0 Likes on 0 Posts
Default

You'll be surprised.. I will PM you with details

Alan
Alan is offline  
Old 03-22-2013, 10:56 PM
  #54  
928sg
Resident 928 Modiholic
Rennlist Member
 
928sg's Avatar
 
Join Date: Mar 2013
Posts: 2,014
Received 3 Likes on 3 Posts
Default

Alan,
I need to PM you about this as well... I have an old one that is semi working.

sg
928sg is online now  
Old 03-23-2013, 12:03 AM
  #55  
Alan
Electron Wrangler
Lifetime Rennlist
Member
Thread Starter
 
Alan's Avatar
 
Join Date: Mar 2002
Location: Phoenix AZ
Posts: 11,930
Likes: 0
Received 0 Likes on 0 Posts
Default

jp did you ever get any more made? - Just had run on these... (4 in one day) supplies are now low...!

Alan
Alan is offline  
Old 03-23-2013, 12:10 AM
  #56  
jpitman2
Addict
Rennlist Member
 
jpitman2's Avatar
 
Join Date: Dec 2002
Location: Australia
Posts: 4,689
Likes: 0
Received 0 Likes on 0 Posts
Default

Bugger, only have a couple of dozen left !
How many do you think you might need?
jp
jpitman2 is offline  
Old 03-23-2013, 12:17 AM
  #57  
Alan
Electron Wrangler
Lifetime Rennlist
Member
Thread Starter
 
Alan's Avatar
 
Join Date: Mar 2002
Location: Phoenix AZ
Posts: 11,930
Likes: 0
Received 0 Likes on 0 Posts
Default

jp - well if you could spare 15-20 that would be great...?

Any amount is good!

Alan
Alan is offline  
Old 03-23-2013, 01:18 AM
  #58  
VegasGnome
User
 
VegasGnome's Avatar
 
Join Date: May 2010
Location: Las Vegas, Nevada
Posts: 150
Likes: 0
Received 0 Likes on 0 Posts
Default

Alan, PM sent.
VegasGnome is offline  
Old 03-23-2013, 01:52 AM
  #59  
jpitman2
Addict
Rennlist Member
 
jpitman2's Avatar
 
Join Date: Dec 2002
Location: Australia
Posts: 4,689
Likes: 0
Received 0 Likes on 0 Posts
Default

aLAN,

WILL get some in the mail to you soon.

jp
jpitman2 is offline  
Old 03-23-2013, 08:43 PM
  #60  
RFJ
Addict
Rennlist Member
 
RFJ's Avatar
 
Join Date: May 2010
Location: SW FL
Posts: 924
Likes: 0
Received 0 Likes on 0 Posts
Thumbs up

You guys are GOOD.
RFJ is offline  

Thread Tools
Search this Thread
Quick Reply: Metal Gas Cap Pawl Installed


Contact Us - About Us - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.
 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in: