Amazon Estate Fuel Filler Cap. Alternative Lockable option

[Palmer 221]

I was never keen in the saloon filler cap on the estate, looks clumsy if you ask me.

Last week i noticed a BMW 02 filler cap on eBay at a price i thought would be worth a punt. wasn't a direct swap but turned into a nice washed out Saturday project.

heres a pic of the cap, to the top right is the BMW cap innards, unfortunately the diameter of a BMW 02 is considerably bigger then a Volvo


so after much consideration, i thought i bolt the innards of the Volvo cap to the BMW

Everything in the BMW cap is an interference fit, so peals apart quite easily.
HOWEVER Volvo caps ARE INCREDIBLY OVER ENGINEERED, easy to change seals but a nightmare to take apart.

BMW cap
cap

After cutting and grinding the Volvo cap, I bolted the housing of the Volvo cap to the baking plate to the BMW, the plate is ideal as it pops out, provides a secure mount and allows the BMW lock and rubber seals to be used




The lock housing on the Volvo required drilling to take the BMW lock


Not pictured here, but when the peg has been installed the lock is complete.


and on the car...

[Volvorama]

Hi - Your original cap was for a saloon, I believe, so it would have had a vent hole that lets fuel out on an estate when you turn right. The estate caps look like your BMW option and have no vent, this being provided in the filler neck (check out the little rubber pipe behind the trim panel).
Mine uses an aftermarket cap from the 70s which is black plastic on the outside. It mostly doesn't leak.
Perhaps you can seal the vent on your cap?

[Derek UK]

Nice work but it still sticks out a LOT when compared to the original bar type but non locking Estate one. What is the number stamped on the plate that covers the locking bar, it has two screws holding it on.