After my fuel cap broke, it sat on my workbench for a while as I pondered what to do with it.  I decided to try and fix it.  I bought a Stant 10640 fuel cap and installed it on the car.  I marked the 12 o'clock and 6 o'clock edges with it properly seated on the filler neck.  Then I also marked the inside of the broken Mustang fuel cap to designate the vertical Mustang emblem.  

I cut the ears away from the Stant cap with my Dremel, and used my ball-peen hammer to make the inner center of the Mustang fuel cap concave.  I test fitted the Stant cap, and pounded the Mustang cap until there was a reasonably tight gap between them.  Then I made sure that my alignment marks were properly matched, and tacked the Stant cap to the inside of the Mustang cap (it took a couple of welds before I realized that I needed to protect the rubber flange from heat, and I removed the cable because it was getting in the way).

So now my Mustang gas cap is functional and when it's tight, the Mustang logo is properly oriented.  As a side benefit, if I'm feeling contrary, I can put the cap on so the Mustang emblem is upside-down (couldn't do that before because of the large tang on the original cap).

The welds are tacky, it looks awful and needs to be cleaned up, but it works.

Last edited by John Ha (10/26/2024 6:13 AM)