Gas Cap w/Cover Issues - Need More Gasket?

[havinnoj]

Hey Fellas - I have tank covers on both bikes, and when I try the Project 321 caps, they don't screw down tight enough to seal (i.e. gas gets out from the cap and leaks down).  I thought a second gasket would fix the issue, problem is securing it in place (the caps only have a lip thick enough to "hold" one gasket). 

Any suggestions?

[havinnoj]

Sure, cut the lip on the cover down the thickness of the seal, or a little more, just to be sure it clears. Wrap the cover where you want to cut it, to show how deep you need to cut.
desertR

Thanks for the reply, can you explain more?  I don't think I follow.  If I cut down (cut out) the cover where the cap sits that would solve the problem I assume; HOWEVER, then nothing to hold the cover on on the 89 style tank.  Plus the red tank would show below the cap which would look odd.   Maybe I'm missing what you're meaning.

[croat1]

Maybe glue the second gasket to the one that sits in the lip.

Joe

[broken1]

Maybe glue the second gasket to the one that sits in the lip.

Joe

I vote X2 for Joe's idea... I got some vulcanized C/A glue at a hobby shop to fix a 2 piece air intake boot on my XL200 dual sport a few years ago & i just hit 1000 miles on that repair as of today & it's still holding strong. I also used it to glue the nylon rub block back onto the rubber chain guard strip on the oem 250R swing arm skid plate at the same time & it hasn't come off yet. Also made a set of hauler type paddles with it for an rc car.

[havinnoj]

Ah interesting. Machining the bottom would be good but I'd lose some flexibility in the future possibly but that's a good idea.  I'll check on the glue Kevin, that could be an easy fix.