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02-24-2016, 05:30 AM
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Join Date: Aug 2008
Location: Jacksonville, FL
Posts: 522
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Use a vise
Quote:
Originally Posted by tthrew
I have new (engraved) Usher fuel caps for my 7A. How do I adjust the tension so they latch (caps are too "fat" right now)? I see from earlier posts to place the "ears' in a vise and hope the pin does not break when moving the jam nut. I read in another post to heat up the plastic on the jam nut..... Looking for suggestions.  Thank you!
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To loosen that nut, open the cap lever, squeeze the lever ears tight between some wood in a vice, Carefully unloosen the nut. Adjust the lower plate. Tighten nut. I also carry a couple spare replacement hinge pins by cutting 3/4 long sections from the smooth portion of a 1/16 drill bit.
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Wendell VAF#1832
RV-6A 3/4 done...N48JE Reserved 
Build site: www.mykitlog.com/weneng
Donated to VAF in 2020
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02-24-2016, 06:54 AM
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Join Date: Jul 2009
Location: Mojave
Posts: 4,652
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I use music wire for the roll pin replacement and give everything a shot of LPS every few flights.
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WARNING! Incorrect design and/or fabrication of aircraft and/or components may result in injury or death. Information presented in this post is based on my own experience - Reader has sole responsibility for determining accuracy or suitability for use.
Michael Robinson
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Harmon Rocket II -SDS EFI
RV-8 - SDS CPI
1940 Taylorcraft BL-65
1984 L39C
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02-24-2016, 08:46 AM
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Join Date: Jun 2010
Location: Stilwell, KS
Posts: 1,096
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Hey, great thread! I thought I was doomed to carrying around a can opener to check my fuel unless I buy the fancy deluxe cap inserts. New O-rings, pins and fuelube are on the shopping list... and VAF dues pay for themselves again. 
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Katie Bosman
RV-3B sold, but flying!
Next project: ???
Builders gonna build...
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02-25-2016, 01:19 PM
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Join Date: Jan 2007
Location: Picton, Ont., Ft. Myers, Fl
Posts: 294
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Adjustment
Quote:
Originally Posted by WenEng
To loosen that nut, open the cap lever, squeeze the lever ears tight between some wood in a vice, Carefully unloosen the nut. Adjust the lower plate. Tighten nut. I also carry a couple spare replacement hinge pins by cutting 3/4 long sections from the smooth portion of a 1/16 drill bit.
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Would not put the ears in a vice... If the nut is very tight(mine was), the ears will break, ask me how I know! Think it might be better to find a way to tightly hold the cap itself.
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Dave Main
Membership due Oct., 2020
RV-4 0-360-188 Catto 3-blade C-FTDQ...
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02-25-2016, 02:03 PM
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Join Date: Aug 2008
Location: Jacksonville, FL
Posts: 522
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Careful is key word..
Quote:
Originally Posted by 777Dave
Would not put the ears in a vice... If the nut is very tight(mine was), the ears will break, ask me how I know! Think it might be better to find a way to tightly hold the cap itself.
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I've done two that way with no problem. 3/4 pine between the ears and vise metal was key for me. Perhaps a spray of penetrating oil might have helped. Definitely do not jerk it.
__________________
Wendell VAF#1832
RV-6A 3/4 done...N48JE Reserved 
Build site: www.mykitlog.com/weneng
Donated to VAF in 2020
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02-25-2016, 02:25 PM
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Join Date: Mar 2014
Location: Alabama
Posts: 127
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Ditto
The threads are in the lower flange below the large o-ring. If you clamp the ears, the torque is limited to the strength of the shear pin. Hold the bottom flange to un-torque. Ask me how I know!
Quote:
Originally Posted by 777Dave
Would not put the ears in a vice... If the nut is very tight(mine was), the ears will break, ask me how I know! Think it might be better to find a way to tightly hold the cap itself.
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02-28-2016, 03:57 PM
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Join Date: Jan 2015
Location: Peoria, IL
Posts: 69
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Got the nut loose!
I tried holding the bottom flange itself with my gloved hand (I needed a stronger hand, because that did not work). The vice I had at my hanger was small, would not open up enough for the flange, so, I put the ears in the vice (soft jaws) and also held on the flange with my hand and the nut broke loose.  "Lady Luck" was with me - the pin did not break. Once loose - the nut was easy to move by holding the cap with my hand. My new engraved caps are installed. I purchased them from Bill at RVengraving. Bill had some health problems and was slow delivering (he called me and explained his situation, I told him no problem, I was not in a hurry). Bill is back to work now and he did a super job. Thank you VAF members for your advice!
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Tim
RV-7A N54LH O360 CS 1000+ Hobbs
Joined VAF 2015
2019 VAF dues Paid
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02-29-2016, 01:42 PM
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Join Date: Nov 2005
Location: Zeeland, Michigan
Posts: 398
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Adjustment
Do not put the "ears" in a vice. Make sure the latch is closed, hold it your hand with a glove or cloth. Use an open end wrench and loosen the nut. If you've never worked on one before take it completely apart by removing the nut and then twisting the lower 1/2 completely off the threaded shaft. Clean all the parts and lubricate with fuel lube or something similar. As someone else said make sure to lubricate the shaft and small O-ring also. It takes a little effort to get them to fit well. You should NOT have to force the lever down or up with much effort. If it's really hard to move or you feel it needs to be that tight to prevent leaks it's not adjusted correctly.
Gary
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02-29-2016, 05:17 PM
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Join Date: Jul 2005
Location: Hubbard Oregon
Posts: 9,035
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There has been a number of different configurations of Usher's fuel cap over the years. The early ones just required turning the nut to make the adjustment. The later ones require loosening the nut and turning the bottom plate.
At one point caps were made with a plastic glide at the base of the latch to help it open and close more easily. It did not work. After a while the plastic gets deformed to where the latch will no longer fully close and it will be hard to open and close. These caps can be upgraded with the later version stainless plate.
Bottom line.... If you are working on an older RV, you need to figure out what version cap you have.....
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Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.
Scott McDaniels
Van's Aircraft Engineering Prototype Shop Manager
Hubbard, Oregon
RV-6A (aka "Junkyard Special ")
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03-06-2016, 10:23 AM
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Join Date: Aug 2011
Location: LaCrosse, WI
Posts: 37
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Fuel caps guide
My "older" RV-4 has neither the plastic nor the metal guide under the latch. The latch presses down directly on the small o-ring. Can the new metal guide be installed on these caps?
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