Aviation and automotive vented fuel caps are designed to keep water out of fuel tanks but they are sometimes not entirely effective.  Rainy and windy conditions can lead to water leakage through the vent of an otherwise functioning fuel cap.  It is especially important to keep aviation fuel free of water for flight safety.  This guide describes a method to make a protective cover for eliminating leaks in vented fuel caps.  This method should be universally applicable to essentially any fuel cap shape.  I made it at TechShop in San Jose, California (www.techshop.ws).

Step 1: Materials

1/16” HIPS sheet (available from Professional Plastics in San Jose) cut to a 13 ¼” x 13 ¼” square

Vented fuel cap

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