Bilal928S4

For evrybody that does not see the pawl, i have attached a picture of the broken piece.

9two8

Just to confuse things further...,
.., I have this seal with the thin lip uppermost in the bottom of my gas cap,, ( so the softer edge mates to the top of the filler neck when screwed down ) there is also a seal around the filler neck ?

Ken
80 928 S 4.7
5 Speed

UK

Alan

I do have more of the mild steel pawl blanks availabe if needed...

jp - I'll let you know when I get down to the last few.

Here are some photos of my aluminum blank from jp - it was finessed a bit more shown than these pics before final assembly - but you can see the general dimensions used

Alan

Bilal928S4

Alan,
As JP has posted the hole at the bottom is not a standard size. What did you use to make that hole?
Also did you use a drill bit to make the "C"?
Thanks

Alan

Due to its function the hole size it not that critical, mine is oversized a little - doesn't matter.

I drilled it in a drill press with a workpiece vice, then I use a milling bit for finishing (not shown).

Filed the rest (teeth, bottom, sides) by hand to finish & polished the bearing surfaces a bit too with a dremmel for easier movement & less wear.

Being aluminum is was very easy to work - steel would be more difficult - but jp's blanks are precise - you only need the hole and cam space machined.

Trial of the fit of the pawl is pretty quick - no need to assemble the whole cap to test for operation - just use the while part and the lock barrel together

Go incremental on the hole depth and profile of the cam gap...

Alan

G Man

I was curious as to how / where the seal on the outside of the filler neck sealed when the cap is in place. I put a light coating of grease on my seal and put the cap back on and tightened it down a couple of clicks. When I removed the cap I could clearly see that grease had transfered to the flat surface towards the bottom of the cap. I used the pics that were posted by Bill Ball and GuardsRed as examples. The first pic shows the seal and the second pic shows where the seal makes contact as indicated by the arrow. If you look close you can see a black mark left in the cap where the seal makes contact.