A classic design of its own,...
A classic design of its own, the LeMans gas cap was standard equipment on exotic and racing sports cars of the performance era. We acquired this polished aluminum beauty, PN 423411C, from Aeroform for installation on our '76 Stingray project.
There is no arguing the fact that when it comes to Corvettes, even a utilitarian device such as a gas cap takes on a stylistic identity. Sure, we can even look at the OEM offerings on the C3, and here we'll find a prominently placed door, in most years adorned with an attractive emblem. The most basic setup carried a racy presence, especially when compared to most other vehicles of the era.
While the OEM door-on-deck arrangement is nice, there is definitely room to step up the performance statement. One component that accomplishes just that is the aluminum LeMans cap. Virtually ubiquitous on road racing and special-purpose sports cars back through the '60s, the LeMans fuel cap was found capping the fuel tank on all manner of machines. Corvette C3 examples could be found on the outlandish Baldwin Motion specialty cars of the period. With its chiseled aluminum shape and purposeful design, this piece is timelessly classic even today.
Our project '76 Stingray has undergone some extensive body modifications, and the overall theme is going to be anything but modest. We were inspired by the look of yesterday, and set on the idea of adding the LeMans cap to our substantial list of custom modifications. There are two approaches to mounting one of these units: either fixing the cap directly to the fuel tank to replace the existing cap system, or deck-mounting the cap in a faux installation, retaining the OEM cap underneath. While a true tank-mounted installation is the more "pure" approach, the existing tank must be removed and modified to accept the flange mount. While this makes the installation functional in the sense that the new cap assembly actually seals the tank, the much more common installation is to mount the new cap assembly to replace the OEM hinged door, while retaining the stock filler neck and cap.
We ordered our cap assembly from Aeroform and were rewarded with a brilliantly polished work of art. With a neck length of one inch, the unit is the perfect height for a deck installation. The actual install requires some fiberglass work and filling, but it was worth the effort since the finished installation provided just the look we were after.
| Difficulty Index - 3 Wrenches |
| Anyone's Project: no tools required | 1 Wrench |
| Beginner: basic tools | 2 Wrenches |
| Experienced: special tools | 3 Wrenches |
| Accomplished: special tools and outside help | 4 Wrenches |
| Professionals Only: send this work out | 5 Wrenches |
The gas cap kit comes with...
The gas cap kit comes with a base flange that is threaded to accept the spring-loaded quick-release hinged cap assembly. This has all the seals to be fully functional if mounted directly to the fuel tank, though we will be doing a deck-mounted installation.
Installing the cap requires...
Installing the cap requires building a flanged mount into the stock fuel door recess. We laid up a thick sheet of fiberglass using polyester resin and multiple layers of fiberglass mat, and then cut a flanged mounting ring slightly larger than the mounting flange of the cap assembly.
After grinding out the lower...
After grinding out the lower lip of the OEM cap recess, we trial fit the fabricated flange and LeMans cap several times until we achieved the lowest mounting height practical. The cap needs to be high enough to clear the hinge and latch through the full range of motion. We used Mar-Glass to bond the flange in place and fill the original finger depression, and to reshape the door recess to its new shape.
Mar-Glass is reinforced with...
Mar-Glass is reinforced with fiberglass strands, and is much harder to sand and shape than regular body filler. We roughed out the shape with No. 40-grit sandpaper, and then smoothened with No. 80-grit.
This is the form of the finished...
This is the form of the finished recess with the flange installed. Note the recess is made more vertical and smaller in diameter to match the neck of the new cap.
A final test fit was performed...
A final test fit was performed to make sure the cap fit properly and that the mechanism has adequate clearance. We gave it 1/8-inch clearance at the tail of the hinge as it swings past the edge of the recess.
Satisfied with the fit, we...
Satisfied with the fit, we proceeded to the final smoothing with conventional body filler. A thin smear of filler was spread over the entire reworked area to perfect the surface.
After a final sanding with...
After a final sanding with No. 220-grit, only a very thin layer of body filler remained, and the reworking of the recess is completed, ready for primer.
Next, we dropped the flange...
Next, we dropped the flange into the reworked recess and marked it for the fasteners. Make sure the flange is clocked so that the cap will screw down in the correct orientation, and that the pattern is symmetrical and square to the body.
We drilled four 9/32-inch...
We drilled four 9/32-inch holes for the 1/4-inch fasteners, which gives a little tolerance and allowance for paint and primer buildup.
Our kit came with stainless...
Our kit came with stainless steel hardware and locknuts for a long lasting and trouble-free installation. Snug the fasteners down tight, but be careful not to over torque and unnecessarily stress the fiberglass.
Success! Here we have the...
Success! Here we have the completed install. A snap of the quick-release latch of the LeMans cap and the OEM cap is easily accessed through the large opening.
Even at the bodywork stage,...
Even at the bodywork stage, the new fuel cap looks as though it belongs on the massive expanse of our Corvette's rear deck. Looking at this brightwork makes us all that much more eager to see the completed project wearing new paint.