by MULEFLY » Wed Oct 22, 2008 3:04 pm
Folks, folks, folks, you are making this much too difficult. I am working with this exact issue right now as I had a "never again" moment a few days ago that I have been too busy to write up yet, but there is a very easy and inexpensive solution.
Lacquer thinner. Wenkman has posted this tip several times on Delphi over the past few years... either cap will regain flexibility (and size--- swell up) if soaked in Lacquer thinner for a few hours. I currently have the Webco style caps but it works on the originals too.
I use a old frozen food container, of suitable size that it can be placed in a zip lock freezer bag so the LT doesn't evaporate. Disassemble the plug and put the rubber stopper in the solution for about 3 to 6 hours. I works wonderfully and seems to hold a "renewed" condition for over a year.
Don't let it set overnight or for "days"... it will grow too much. But currently I am finding that about a 6 hour "bath" works great.
All the best!
Jim