Fuel tank cap lever repairs

[Steve65E-NC]

    My levers snap down with less and less authority.  I think the problem is purely the rounding of the corner on the lever.  This corner cams between lever toggled up and lever toggled down positions.  The cap casting itself shows no wear in this area.  Nothing about the lever, except the corner has or shows any wear.  Has anyone had any luck in doing a weld build up and file re-shape of this area.  Seems to me that this is a basic repair that could be signed off by any AP mechanic.   It is a simple dis-assembly to get down to the bare, apparently Aluminum, part.  I assume it is an aluminum die casting, wonder what rod and how best to do a weld build up.  I know that new caps are priced at over $300 and that no replacement parts are sold by the manufacturer down in Naples, Fl. 

[danb35]

I've not tried to weld it up, but some judicious use of a file will give a sharper corner, which will give the result you're looking for.

[danb35]

[hit by the forum bug, double post]

[jetdriven]

That sounds like a job for the hangar fairies.  Mystical.  Cheap.  

[jetdriven]

error

 

[carusoam]

Try the adjustment first???

 

-a-

[Jmdunn123]

My levers snap down with less and less authority.  I think the problem is purely the rounding of the corner on the lever.  This corner cams between lever toggled up and lever toggled down positions.  The cap casting itself shows no wear in this area.  Nothing about the lever, except the corner has or shows any wear.  Has anyone had any luck in doing a weld build up and file re-shape of this area.  Seems to me that this is a basic repair that could be signed off by any AP mechanic.   It is a simple dis-assembly to get down to the bare, apparently Aluminum, part.  I assume it is an aluminum die casting, wonder what rod and how best to do a weld build up.  I know that new caps are priced at over $300 and that no replacement parts are sold by the manufacturer down in Naples, Fl.

[Jmdunn123]

This is a specialty welding procedure. It requires a high frequency machine to do the build up. The metal would have to be pre-heated to do a stick welding procedure. Take this to your local machine shop. Should be able to get it done for less than $100. Aluminum welding is not something that should be done by an amateur.

[carusoam]

Check that the piece is adjustable first, before going through the effort of welding.

If you have tried the adjustment already, I apologize...

Best regards,

-a-

[MARZ]

What shape are the O rings?  Less thickness there would give you more "slop" in the lever - next is a turn or two on the nut.  IMHO I would not think that you've operated the levers enough to wear down the surface.

[DrBill]

I talked to SteveNC today at a FAAST seminar.  He sucessfully rebuilt a worn cap lever.  Added material to the surface then milled the surfaces square.  Now they snap like new.

BILL

[fatter36]

i just filed it square without adding more material.  worked fine.

[Skybrd]

Keith at Bakersfield aviation KBFL Bakersfield, Ca. Has fixed mine by welding and grinding. Contact him for help. don't have his number but you should find Bakersfield Aviation on the Internet. Good luck.