Ford Ka 2005 - Help! Rust repair on Ford Ka petrol cap stalled. - Shifty Geezer

I have the usual Petrol Filler Rust Problem on my Ka, and took some sandpaper to it this morning to clean it up. However, I've found the rust is worse than I thought with some holes around the filler, so I need to take the whole thing out.

In theory I just need to undo one Philips screw and twist and pull out the fitting, but the screw won't budge at all. I've used 3-in-1 easing oil, left it to work, and tried both a superb quality screwdriver that has worked on every other screw it's been challenged with, and an electric screwdriver that I can get my whole weight behind. It doesn't move at all and I can't persist in trying without risking chewing the head up.

So now I have bare metal and rust exposed to the elements, but I can't continue the repair job if I can't remove the filler fitting. I'm at a loss what to do now!

Ford Ka 2005 - Help! Rust repair on Ford Ka petrol cap stalled. - hardway

I usually try my small chisel on the perimeter of the head,

trying to notch enough to free the b***** off.

or worst case would be to knock the head off!

Ford Ka 2005 - Help! Rust repair on Ford Ka petrol cap stalled. - jc2

Impact driver?

 

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