Filliing/Plugging the Gas Tank Hole on the Cab
 

I'm new to fabrication and welding, I'd just like to share my idea and hope it helps someone. Be easy on me.

I removed the tank from the cab and put in a "under bed" tank. I was left with a hole in the cab. I'm not a good enough welder to put a shave plate and I'm definitely too broke to paint after that. So I decided to modify a cap to seal the hole and, as a plus, retain the stock look.

Here is the Video for those interested


https://www.youtube.com/watch?v=tSJAcwcTjm0&t=8s




And here is the tutorial for those that prefer pictures.

Supplies:
4 inches of all thread and 2 matching nuts ... or bolt and nut.
Gas Cap from auto part store
Filler neck grommet
Some thin metal for making a huge washer.
Optional: peel and seal or equivalent

Tools:
Welder: Or epoxy, JB Weld, Etc.
Something to cut metal: I used a cheap jigsaw and metal cutting blades
Drill and drill bit slightly larger than thread width


Get yourself a cap for under $10 at the local auto part store. Weld a nut on the inside of the cap. You can also use epoxy, JB Weld, or some other adhesive if you don't have a welder.

Screw in some all thread and tack it so it wont spin off

Or, you can just use a bolt instead of a nut and thread.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Cut out a large washer from the steel. I used 2-3mm thick steel diamond plate that I got from the scrap yard. Drill a hole in the center big enough for you thread/bolt. You want this to be slightly larger than the Filler Neck Grommet. I added Peel and seal on the back just for a cushion and a better seal.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Test fit and cut the thread to size. I used about 4 inches. I rounded the end of the tread to make it easier to thread on the nut.

Set the cap in the hole. Center it the best you can. Slide the plate on the back. Push it flush against the back of the grommet.

Screw the nut all the way down do it pinches the grommet between the cap and plate. Make sure it is center up.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

And your done! it looks great to me. Still looks factory. And there is no hole that water can leak through. I sprayed it with a water hose to make sure :D

I hope this helps. This was just my cheap and easy way to cover this hole. Let me know what you think!

The video for this is:

https://www.youtube.com/watch?v=tSJAcwcTjm0&t=8s


And it never hurts to subscribe to the channel. I have a ton of things that need to be done to the truck so ill be regularly uploading new videos.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

I'm the guy who commented on youtube, cool to see that you're a member on here.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Good job. An easy way to do the same thing is find an old tank and just cut the filler neck off and reinstall it.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Well I appreciate it! I’ve been a member on here for a long time. This forum has helped tremendously with my truck, so I figured I could return the favor. Subscribe and share if you could!

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Yeah that would have been a great option. In retrospect, I would have cut the original neck off before scrapping the tank.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Best one I have seen it to use it as a locking storage with a gas cap and cap the tube off and secure from inside.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

man... that's a waaay better Idea! A smugglers spot! lol.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Good Job, Nice option.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

clever and clean.. thanks for taking time to share :)

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Subbed your U tube channel & liked.
Great idea:metal:









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Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

I wanted to keep my original cap since the patina matched the paint. I installed a new filler neck grommet and used a 5" piece of 1" angle steel as a brace on the inside of the cab. I drilled a hole in the angle for a sheet metal screw to secure the cap through its center hole. I was only able to catch one or two threads, so I drilled two smaller holes on each side of the center hole of the brace and used wire to safety-wire the cap to the brace using the locking tabs/ears on the cap. That should keep the cap from bouncing down the highway should the screw loosen.

~Tim

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

god bless the search function for the forum. This is EXACTLY what I was looking for. Has it held up well? any leaks or anything?

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

That is a nice option. I removed my tank and want to classic look of the filler neck and cap. This looks like a good way to go.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Thank you! I wanted to make a good option that didnt require having to paint anything. This worked out great and I dont have to worry about it leaking.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

i did this years ago only i used a carriage bolt with a litt rtv where it goes though cap so far it has held up great

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

That was my biggest issue, I didnt want to put a bolt through the cap I wanted it to be nice and smooth on the outside. I think it came out ok. Do you have a picture of your?

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

why did you cut the filler neck off of the original tank and use that and the original cap to plug the hole? Ive even heard of people putting a kill switch in there.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

When I Relocated the tank, I sold my old tank. i shoved a beer can in there for a couple weeks until I made this contraption.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

That would make a killer beer dispensing device. Remove the cap - pull out a beer.

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

hahaha! That is great!

Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

Nice job. I did that on my K10 build. Didn't mess with the tank fill neck at all.

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Re: Filliing/Plugging the Gas Tank Hole on the Cab
 

perfect ! Exact same solution but yours looks 1000X better than mine! Thanks for sharing.