Are you tired of fuel dripping inside your trunk?
Are you tired of getting high from the gas fumes when you go to the grocery store?
Are you tired of fuel pouring out on the side of your car, when you hit those hard left hand turns?
You say you don't have $250 for a NOS, out-dated OEM rubber filler hose for your 510?
Then this quick easy cheap mod could be for you. (no welding involved)
This is a HowTo, on another way to replace that old rotted out filler on a 510 using about $10-$15 in wrecking yard parts.
My goal was to come up with a filler neck that was super easy, super cheap, and didn't require any welding. I'm a fabricator myself, so I can build anything I want, but I wanted the challenge of coming up with one, without using any expensive tools, lol.
I did not remove my tank to install this, The tank you see in the pics, is an extra one I have around for mockups.
1) 88-93 Mazda B2200 filler neck
2) 91 Isuzu Pup filler hose (not sure what other years match it yet) (If anyone finds a good source for NEW hoses please post it)
3) A couple feet of new 5/8" vent hose
4) A newer style plastic (thread on type) Nissan gas cap (or the Mazda one that was on the filler when you got it at the wrecking yard)
Tools that help make it easier:
1) Basic 4 1/2" grinder (can be done with a hacksaw and flat file if needed)
2) Harbor freight med size tail pipe expander (not needed but helps) I think I paid about $8 for it.
3) Heat gun or blow dryer
This is the ugly thing that has been in there for way too many years: (It had to go)
***You do not need to remove the tank to do this mod.***
I'll be showing a modded and un-modded part of each thing.
So we start with the 91 isuzu rubber filler hose. I cut 2" off one end and 1" off the other end like so. (note where the bend is, so you cut the right amount off the correct ends)
Next we grab the Mazda B2200 filler neck and cut off the extra hanger.
Then we take the 510 gas cap ring and make the inside hole larger. I do this by just grinding the top of the bump down, until the center falls out. (then it's just the right size with a perfect round hole)
Now we have this:
Now working with the end that I took 2" off, insert the expander into the hose about 3" or so. Then use the heat gun to warm up the rubber, (slowly expanding it), until it will fit over the fuel tank opening.
Then mount the neck itself (the metal part) using the original 510 ring we modded on the outside. Make sure to mount it with the hinge of the flapper door on the top, and so the vent tube faces the rear of the car. Make sure the vent tube doesn't get in the way of the trunk hinge.
Then hook the rest up and it should look like this.
Now this is in no way the only way or even the best way to do this, but it was a fun project, and makes it so much nicer at the pump. No more gas fumes is a great bonus as well, lol.
So as for testing so far:
It fills up like a normal car now, it's great. You can lock the handle and go. I haven't filled mine to the top yet though, (I only run my tank half full for weight balance), so maybe someone else can report back on that some time. I ran the crap out my car, (drifting around corners etc...), and it never drip at all on the inside or outside. No more smell. The only minor hiccup i've found so far is, if you are not careful, you will drip a little fuel when you remove the pump handle because of the angle.
Let me know if you have any questions
*****This is a post on how I did my own filler neck, I am in no way responsible for anything anyone else does to them selves or anyone else by reading this information. Read at your own risk. Fuel is very very dangerous and can kill you in more ways than one. Do not try anything like this at home*****