So as many of you were aware I had to get a locking gas cap for my '68 FJ40 after the gas was stolen this past weekend. Of course there is not a locking gas cap that is made for a 1968 FJ40, so I also ordered a filler neck from a late model 40. Now I already had the understanding that the filler neck would need to be modified to fit and I felt up to par with the task. So for the price of $75, I got a new locking gas cap and a very nice zinc plated filler tube from CCOT.
Well, it came in the mail yesterday. Right away, the gas cap did not even fit in the neck, as it was too long. I had to disassemble the lock and cut the 2 screws holding it together in half to shorten them. I also had to remove some sort of plastic flange on the rear of the cap to shorten it.
Once that was taken care of, I noticed that the holes that hold the neck to the body were all in the opposite place that they needed to be....so I had to drill and tap all new holes for the screws. Well the neck has a slightly smaller diameter than the early model 40's so naturally only 2 of the 3 screws needed to mount the neck are actually functional. The top two screws are functional (going through the lip of the neck). The bottom screw goes past the lip and has a washer and nut on the back side of the lip; keeping pressure against the lip, holding it against the body. Additionally, because of the smaller diameter, there were gaps where moisture could enter the cabin so I made a gasket out of cork rubber.
The 45 degree elbow supplied by CCOT was also too long had had to be cut down. The vapor return hose is also sitting at about 190 degrees instead of about 280. I hope this does not case any problems. Ah yes, the filler neck is also too long and had to be cut down by about 3 inches.
All in all though, after a few hours of work, I got everything installed and it looks great! So, for a few hours work and about $75, you can have a very nice locking gas cap on an early model FJ40.
I used Grade 8 M6 screws, washers, and nuts.
Pictures (sorry for the poor quality cell phone pictures)
Well, it came in the mail yesterday. Right away, the gas cap did not even fit in the neck, as it was too long. I had to disassemble the lock and cut the 2 screws holding it together in half to shorten them. I also had to remove some sort of plastic flange on the rear of the cap to shorten it.
Once that was taken care of, I noticed that the holes that hold the neck to the body were all in the opposite place that they needed to be....so I had to drill and tap all new holes for the screws. Well the neck has a slightly smaller diameter than the early model 40's so naturally only 2 of the 3 screws needed to mount the neck are actually functional. The top two screws are functional (going through the lip of the neck). The bottom screw goes past the lip and has a washer and nut on the back side of the lip; keeping pressure against the lip, holding it against the body. Additionally, because of the smaller diameter, there were gaps where moisture could enter the cabin so I made a gasket out of cork rubber.
The 45 degree elbow supplied by CCOT was also too long had had to be cut down. The vapor return hose is also sitting at about 190 degrees instead of about 280. I hope this does not case any problems. Ah yes, the filler neck is also too long and had to be cut down by about 3 inches.
All in all though, after a few hours of work, I got everything installed and it looks great! So, for a few hours work and about $75, you can have a very nice locking gas cap on an early model FJ40.
I used Grade 8 M6 screws, washers, and nuts.
Pictures (sorry for the poor quality cell phone pictures)
