"Nick" wrote in message
...
I would try a large diameter, short brass nut, washers and bolt into a
tight
fitting hole with a "suitable-for-fuel rubber" washer each side - then
drill
and tap the brass bolt and screw in the (or a new) petrol tap.
This assumes you can get a nut into the right position and it will self
hold
whilst tightening up ( use loctite ).

If not, and this assumes the plastic is thick enough, drill and tap a
larger
hole and either fit a petrol tap in direct, or a bolt which you can then
drill and tap perhaps with a washer on the outside to strain relieve a
bit.

Or as the others suggest - get a new or s/hand one but then thats not
D-I-Y...

Also depends on "what if it leaks" - a lawn mower/ outboard motor I
wouldn't
worry so much, but if it leaks somewhere where vapours could collect, go
the
new route.

Nick


=======================
This might be a possible starting point:
http://www.screwfix.com/app/sfd/cat/...18109&ts=13268

It depends on what access there is through the filler cap.

Cic.



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