Suggestions on how to remove the unleaded gas restrictor

[kdjones2000]

I am trying to make my 87 924S track ready, and part of that includes removing the unleaded fuel restrictor from the fuel inlet.

I took the aluminum tube out of the car and then proceeded to essentially destroy it while trying to use a hacksaw blade to cut up the restrictor and remove it.

The door is placed into the tube before the ends are crimped over, so it obviously has to be cut out.

My question is what is the best to remove this thing?

Thanks in advance....

[Jrboulder]

Does the euro one have it too?

Porsche 924 944 (1975-1991) Fuel Filler Pipe | eBay

[v2rocket_aka944]

Howabout just running a big fat hose from the tank to the filler hole in place of the tube?

[kdjones2000]

You need a cap to keep gas from spilling all over the track - not going to happen with a hose.

Good point on the ROW cars..... good idea, thx!

If the part fits the early generation 924's as well, then that might be the way to go as well. The restrictor is a LOT easier to remove from the Gen 1 cars than it is from the 924S/944's.

[BikePilot]

I know little of race car prep, but I've messed with desert bikes. We use dry brakes for quick fuel stops and they can be bought as just the break that you then screw/seal onto the top of the moto tank. Don't see why you couldn't attach a dry break to a hose to the gas tank. Probably more work than it's worth though.

[fiat22turbo]

Given that the mount in the body for the filler is round, I can't see where it would be hard to adapt a different round filler port and use hose to connect to the tank and perhaps use a remnant of the stock filler neck cut off below the flap.

Another thought, would a die grinder or a hole saw allow you to cut out the offending bit?

[joeblow]

You can remove the restrictor and flow back float from the existing part. It is one of those serious Pain-In-The-As* jobs but nothing a couple of hours and a few busted knuckles wont cure.

Depending on what tools you have access too you can do it without damaging the soft aluminum fill tube. The problem is that the restrictor is steel and is held in with pressed in dimples which with limited access is all hard to deal with. A small cutting disc on a Dremel tool, long nose pliers, and bench vise with a pipe attachment make it much more doable.

Removing the complete fill tube and going dry break must also have the vent and overflow provisions otherwise you will have other issues so it is by no means a simple mod. I have done this both with the stock tank and with a fuel cell. For stock tank set-up I use the original part.

[kdjones2000]

Joe, that has pretty much been my experience with it.

A complete, total PITA. I don't see how a dremel can be useful for this, given the very limited access.

I was able to get it out but not without some deformation to the threaded end of the fill tube and there are a couple of very small holes where the hacksaw blade cut into the aluminum tubing too much. I ended up using one of those "single-ended" hacksaw blade holders and sawing the piss out of the steel bits, then picking out the pieces with pliers and a blade screwdriver. Again, not without some damage to the tube.

I was looking at PET today and the early fill tubes do not have all of the connections that the 944/924S ones have, so that isn't going to work. The ROW fill tubes probably still have some type of restrictor in them, if only to prevent people from putting diesel into their cars. Not sure about that one.

I am going to see if this one is salvageable, and go from there.

Dry-breaks are not allowed in Chumpcar, so that idea is out....

[jhowell371]

Hole saw?