aluminium deck filler cap

[chubby]

We have aluminium alloy deck filler caps for water and diesel and the slots have become rounded off mainly due to the skipper using various screwdrivers and multitools to undo them rather than a proper key, naughty me!, this makes them difficult to undo especially when there there are other folk waiting at the fuel berth!

They were made by SW and out of production for years, replacements in the chandlery are chromed brass but the thread would fit but will dissimilar metals corrode or would a liberal smearing of grease help?

Anyone got any tips for deepening the slots?

I dont want to replace the desck sockets if I can avoid as underdeck access not good and disturbs pipework.

 

[KAM]

I had the same problem. I had the old slots filled with weld then new slots machined. It worked well but it would probably not be cost effective if you had to pay to have it done.

 

[onesea]

We have aluminium alloy deck filler caps for water and diesel and the slots have become rounded off mainly due to the skipper using various screwdrivers and multitools to undo them rather than a proper key, naughty me!, this makes them difficult to undo especially when there there are other folk waiting at the fuel berth!

They were made by SW and out of production for years, replacements in the chandlery are chromed brass but the thread would fit but will dissimilar metals corrode or would a liberal smearing of grease help?

Anyone got any tips for deepening the slots?

I dont want to replace the desck sockets if I can avoid as underdeck access not good and disturbs pipework.

+1 One of mine is actually seized (X race boat obviously did not use water!) not to badly rounded any tips for shifting?
Watching with interest...

 

[Alpha22]

As they are not permanently immersed in sea water the dissimilar metals thing should not be too much of an issue. I would think with a smear of grease, they would perform brilliantly.

 

[Searush]

+1 One of mine is actually seized (X race boat obviously did not use water!) not to badly rounded any tips for shifting?
Watching with interest...

Pipe wrench like this;

The jaws pivot slightly & turning tightens them. But take care, if it doesn't free it, it will destroy it. They are Very powerfull tools. Mole grips is another idea & putting it on in a couple of different directions may flex the cap enought to free it a little. A kettle of hot water will always help first.

 

[onesea]

Pipe wrench like this......

Searush thanks for that but unfortunately its a flush cap fitting like this:
http://www.marineoemsupply.com/images/products/deck_filler_all.jpg

I have bent 2 keys like this:
http://cdet.co.uk/resources/images/shop/large/8.jpg
trying...

Cannot get to boat to measure but if some one can supply me dimensions of the slot (Early 80's 3 screws fix it to deck) I might be able to get special key made here...

I try to restict myself from tools with potential to destroy as destruction is normal result

When I am home again I will try ice and HW to see if that helps...

 

[Highland laddie]

Aluminium deck filler

A carefully used! angle grinder might deepen the slots depending on the radius of the existing slots.

 

[rotrax]

We have aluminium alloy deck filler caps for water and diesel and the slots have become rounded off mainly due to the skipper using various screwdrivers and multitools to undo them rather than a proper key, naughty me!, this makes them difficult to undo especially when there there are other folk waiting at the fuel berth!

They were made by SW and out of production for years, replacements in the chandlery are chromed brass but the thread would fit but will dissimilar metals corrode or would a liberal smearing of grease help?

Anyone got any tips for deepening the slots?

I dont want to replace the desck sockets if I can avoid as underdeck access not good and disturbs pipework.

Try drilling two 5mm holes -one at each end of the slot. Not so deep as to go right through though! Then make a simple peg spanner with a strip of metal and two 5mm screws at the same spacing as the holes.Good Luck.

 

[Oldhairy]

Onesea
+1 One of mine is actually seized (X race boat obviously did not use water!) not to badly rounded any tips for shifting?
Watching with interest...

This sounds crazy but it works. Soak the threads for several days in very strong black tea.
No sugar

 

[Dazedkipper]

I have seen plastic plugs in chandlers, I think they were by Plastimo (what isn't these days).

Allen bros still make an aluminium deck filler, £65 last year when a friend had to get one.

 

[chubby]

Thanks for all the ideas, I knew the combined knowledge of the forum would help!!!