Monza gas cap installation ring

[tommyboah]

Hi guys. I am currently working on replacing the stock gas cap on my KZ1000R gas tank. I have bought a Monza gas cap along with the installation ring from DCC.

http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-fuel-tank-parts-monza-style-flip-up-fuel-cap-ring-monza-2.html

My question now is how do bolt on the installation ring? I cannot imagine that i will be able to fasten the included nuts from inside the tank. Anyone solved this one before?

I appreciate the input.

Tommyboy

 

[SONICJK]

Why not? Reach 2 fingers in the filler hole and put the bolts on, then fish a wrench in there and hold while you tighten.

Or just get some self tappers and coat them in silicone and drill away hah.

 

[mikeinnh]

Why not? Reach 2 fingers in the filler hole and put the bolts on, then fish a wrench in there and hold while you tighten.

Or just get some self tappers and coat them in silicone and drill away hah.

Agreed. Unless you've got really fat fingers this shouldn't be too hard. Love the look of these caps!

 

[Tim]

Most important - Make sure the installation ring is oriented such that your cap ends up in the right position when screwed down.

So put the ring and cap together FIRST, nice and snug - as tight as it will be installed. THEN line it up on the tank and mark the ring and tank so you can line them up.

Then remove the cap, put the ring back on the tank and mark your holes.

This is intended for a custom tank I think - what tank are you installing it on? If the ring fits over the existing filler hole then you'd be OK too on a stock tank.

 

[tommyboah]

Most important - Make sure the installation ring is oriented such that your cap ends up in the right position when screwed down.

So put the ring and cap together FIRST, nice and snug - as tight as it will be installed. THEN line it up on the tank and mark the ring and tank so you can line them up.

Then remove the cap, put the ring back on the tank and mark your holes.

This is intended for a custom tank I think - what tank are you installing it on? If the ring fits over the existing filler hole then you'd be OK too on a stock tank.

Good tip about the line-up thanks.

This is for my KZ1000R tank http://i.ebayimg.com/t/82-85-Kawasaki-KZ-1000-KZ1000-R-Gas-Fuel-Tank-63L-/00/s/OTYwWDEyODA=/z/li8AAOxy-gBR-GVO/$(KGrHqN,!o0FHiwcFTZYBR-GVOPnYg~~60_35.JPG. The ring is a bit larger than the stock filler hole, so gas may splash out of the stock hole and into the new hole consisting of the ring and Monza cap. Should that cause any issues?

-Tommyboy

 

[CBPayne]

I bought one of those Monza style flip tops from dcc. There pretty sweet, but I got the brass collar ring. I figured it would be easier to install than the way you went. All I had to do was braze on a piece of exhaust pipe that fit inside the collar and then fill in the gap between the current opening and the exhaust. Then all I have to do is screw the collar into the flip top, add jb weld and stick it on. Done! Well not yet, I have to paint the tank first.

 

[o1marc]

I'm missing something here. In the link to the ring it shows a large aluminum flange with the threaded neck and bolt/screw holes around the perimeter. Where does that large ring go? It can't go inside the tank because it's bigger than the fill hole and I don't see how it could go outside

 

[CBPayne]

I'm missing something here. In the link to the ring it shows a large aluminum flange with the threaded neck and bolt/screw holes around the perimeter. Where does that large ring go? It can't go inside the tank because it's bigger than the fill hole and I don't see how it could go outside

You have to buy the cap with the brass ring and the flange is separate. There for two different ways of installation.

 

[tommyboah]

I'm missing something here. In the link to the ring it shows a large aluminum flange with the threaded neck and bolt/screw holes around the perimeter. Where does that large ring go? It can't go inside the tank because it's bigger than the fill hole and I don't see how it could go outside

The large ring you refer to is bolted on the top of the tank by using screws, with the flange sticking up. Then you screw the cap onto that.

 

[tommyboah]

I bought one of those Monza style flip tops from dcc. There pretty sweet, but I got the brass collar ring. I figured it would be easier to install than the way you went. All I had to do was braze on a piece of exhaust pipe that fit inside the collar and then fill in the gap between the current opening and the exhaust. Then all I have to do is screw the collar into the flip top, add jb weld and stick it on. Done! Well not yet, I have to paint the tank first.

I do also have the brass ring, but thought this might be a harder way to move, as I know nothing about brazing. Would you say it's an easy task to braze it onto there?

Just to understand, the pipe you used, does the brass ring press fit onto there or do you screw it on or what?

Dunno what to go for yet, as the brass ring gives a much cleaner look, but the mounting ring also gives a kind of cool look.

 

[o1marc]

The large ring you refer to is bolted on the top of the tank by using screws, with the flange sticking up. Then you screw the cap onto that.

I was confused because they show the gasket on the wrong side of the flange. I've never seen that type set up that did not have some sort of ring on the underside inside the tank also.

 

[CBPayne]

Until then I have never really brazed anything before, but now I have. I went to two different shops for prices on getting this task done. One wanted $50 to $120 and the other wanted $150. All three of us were over complicating things. Well no offense to DCC but they don't tell you how to install this properly if at all. So I called a couple of places and found this shop in southern Florida that I would bet DCC buys there supply of Monza caps from. The guy told me your not suppose to braze the brass collar onto the tank. Which is what all three of us original thought. "There just wasn't enough material." Plus brass would take forever to get hot and you mess up your tank. So I did what the man down in Florida said. Find a pipe that will fit pretty snug. You want find it at hardware store or a plumping specialists, I've already tried. I took the brass collar to advance and starting looking and trying to find something in their exhaust section that would fit. Well it all worked out. Hopefully your tank isn't painted or not to much(primered). It would be in your best interest if you didn't have the tank sealed, because that shit is going to melt. It's a pain in the ass to clean that up. I bought silver solder brazing rods, they worked the best for me. I also practice on some scrap of the same gauge once or twice and then went for it. You may not have a acetylene torch, then I wouldn't recommend this route for you. Someone else may lead you to right tool/torch to use but I had no luck with those small propane and mat gas handhelds. They don't get hot enough! The only problem I had was building up material in the gap between the original opening and the exhaust pipe. I had some pin holes left, so I filled them up with the tank sealer. I used KJS for the tank sealer. I hope this helps. The collar just tightly fits onto the exhaust, I will use jb weld to hold it on in place. Hey don't breath in the fumes of the brazing rod.

 

[tommyboah]

Until then I have never really brazed anything before, but now I have. I went to two different shops for prices on getting this task done. One wanted $50 to $120 and the other wanted $150. All three of us were over complicating things. Well no offense to DCC but they don't tell you how to install this properly if at all. So I called a couple of places and found this shop in southern Florida that I would bet DCC buys there supply of Monza caps from. The guy told me your not suppose to braze the brass collar onto the tank. Which is what all three of us original thought. "There just wasn't enough material." Plus brass would take forever to get hot and you mess up your tank. So I did what the man down in Florida said. Find a pipe that will fit pretty snug. You want find it at hardware store or a plumping specialists, I've already tried. I took the brass collar to advance and starting looking and trying to find something in their exhaust section that would fit. Well it all worked out. Hopefully your tank isn't painted or not to much(primered). It would be in your best interest if you didn't have the tank sealed, because that shit is going to melt. It's a pain in the ass to clean that up. I bought silver solder brazing rods, they worked the best for me. I also practice on some scrap of the same gauge once or twice and then went for it. You may not have a acetylene torch, then I wouldn't recommend this route for you. Someone else may lead you to right tool/torch to use but I had no luck with those small propane and mat gas handhelds. They don't get hot enough! The only problem I had was building up material in the gap between the original opening and the exhaust pipe. I had some pin holes left, so I filled them up with the tank sealer. I used KJS for the tank sealer. I hope this helps. The collar just tightly fits onto the exhaust, I will use jb weld to hold it on in place. Hey don't breath in the fumes of the brazing rod.

Ok, thanks for the info. Seems like the easiest route for me is to go with the installation ring. I have to strip the tank first and bondo a bit before i can drill holes and fit the ring. I will post when I get there.

 

[Maineiac]

Here was my solution:

http://i1200.photobucket.com/albums/bb324/MerchantMaineiac/287BD9B7-D7E1-4C94-9EA7-3F56840B372B-2618-
000001ECE1B24DF0.jpg

To get the cap real tight on the flange, I screwed the flange to my bench, then threaded on the cap. I hope you have the new flange, as the old ones, the pitch was incorrect for the monza cap. I made it work, but would've preferred a perfect fit. To tighten the bolts, I cut down a cheap box end wrench to fit inside the filler neck.