Fuel filler cap fail

[LewisH]

Part of my IVA fail was the "sharp" edge on my fuel filler cap.

Does anyone know where I can source one with a radius edge that will fit? It is the one supplied from Robin Hood and the hole size from the filler neck looks to be around 35mm.

Failing that, does anyone have an idea as to how I could fit a piece of trim around the edge? Reluctant to file off the edge but that may be my last resort. 

[Grim]

a round piece of pipe formed around the cap to prevent access to the sharp edge?

[Sparepart]

Perhaps you could find a plastic end cap ? Something like:-

https://www.comtecdirect.co.uk/product/emtelle-pvc-duct-end-caps/PG4330

This one is just under 100mm, don't know the diameter of your cap. You could trim the length and perhaps wind tape around the outside of your cap to get a tight push on fit. Cut a round hole in the middle so that the key goes in. Then you could form a correct radius to get through the test, and it would not look like a temporary fix.

[sylvia.fry2]

Enlarge the " boot" hole & fit cap flush, If the radius gauge can't reach the edge problem gone.