Unfortunately, BMW only sells new chrome /5 style gascaps with the lock mechanism. I really like the smaller look of the non locking gascaps. I sourced a very good condition aluminum gas cap and unfortunately, the cork gasket is worn.
Luckily, BMW does sell replacement gaskets. I happened to have one in my parts stash, brand new. What I needed to order was a new retaining pin and washer from BMW.
Removing the old one was difficult. I started by shaving the old pin head down with a dremel. By doing so, i was able to remove the old cork gasket and create a flat surface to align a drill bit to drill out the old pin.
I then took the gas cap to my drill press and tried to center my drill-bit as best I could to drill out the old pin. Unfortunately, the drill bit took on the path of least resistance and did not center perfectly to drill out the old pin. And, the old pin’s metal was either extremely hard, or it got hardened from all the heat of the drill bits.
It was one of those jobs that took an hour longer then I had anticipated.
I eventually got it drilled out. Here it is with the new gasket, pin and washer:
I used some JB weld in the old pin hole to fill the area where my drill bit went awry. I then drove in the new pin by tapping it down with a hammer.
She’s now ready for fuel.
I’ve used this product before with reasonable success on about 3 or 4 motorcycles now. In one instance, it started to peel from the roof of the gas tank and large chunks would float in my gas. Once i removed them, everything was fine.
Something must have gone wrong with the prep or paint process. I have a feeling it was from the tank drying upside down and the POR15 dried in a puddle that eventually broke loose.
I have a bunch of tanks sitting around and an extra kit of POR 15. Unfortunately, this process takes nearly an entire day.
Follow the directions and you should be good to go.
Try to do it on a sunny day.
It really helps to have a heat gun to speed up the process of drying out the tanks.
Prepare to get wet or splashed.
TAKE CARE TO PROTECT THE PAINT OF YOUR TANK. If any of the 3 step process gets on the tank, it may leave a streak and damage the paint.
Wear Gloves. (see below)
The vicitms... ready for a day in the sun.
The first two processes require lots of sloshing liquids inside the tank. Then drying. A heat gun helps speed up the dry time. I hair dryer may work too but not as effectively.
This photo was taken after the first step, 'Marine Clean' was used. The Marine Clean removed a ton of the rust inside. When i drained it, the water came out Rust-Red.
It looks like a previous owner used the tank cream or something similar. These chunks, and many more came out after the second process 'Metal Ready'. I ended up using a long screwdriver and tried to scrape off as much of this crap as i could. It was a previous tank coating gone wrong. There is still remains of it in the tank. I hope it doesn't cause problems later on. The POR 15 is such a good sealant, i think it won't be a problem.
Tanks sealed. This process is a messy one. It would help to have an old set of petcocks to use while you slosh the sealant around. then remove them to drain the sealant and dry.
Out on the porch to dry. They were originally in the garage but they stunk up the whole house.
I went Michael Jackson style and only wore one glove. I got the sealant on my other hand and it sure doesn't look like it is coming off anytime soon. I used paint thinner and lots of scrubbing and... well... the wife isn't happy a day later... opps!