Anyone have any suggestions on how to repair broken balancing nipples on some early '90js Mikuni Carburetor Caps? They are for 91-93 Suzuki bandits and are shorter than just about anything out there, and are hard to find. I have 3 carb caps that have the balancing nipple broken off. I suppose I could just seal the holes but then I'd have to swap carb caps around for balancing. See photo of good and broken caps for reference. I also wondered if there would be any issue using slightly taller caps. Katana carb caps from the same era appear to 1/4" to 3/8" 'taller', so I debated sourcing a set of those and seeing if they work. I'm not sure if there is enough airbox clearance. I can figure that out but I'm also not sure if taller caps would affect fueling. Thanks for any help/advice!
Think it will come down to how much you are willing to spend to salvage that. At a glance, I think you could drop it in a mill, counterbore a new hole, and maybe shrink in a new nipple. Would sorta depend on the diameter and if you can get the right tool and material. Brazing might work too.
Yeah, if I were in the position I had to fix it and not just buy another cap for cheap, I would drill it out, ream it, and press in a brass barb with some sealant or something. Those are the plastic type, right? You could also probably get away with using a soldering iron and some filler plastic of similar resin. Might be nylon.
May be helpful. One time I had a leak on the intake side in a 4.3 l v6 intake manifold in a 91 s10. ..I didn't know anything...I still don't. I didn't want to do the swap. I batched up a load of JB weld and popsicle sticked it all along the mating surfaces of the manifold assembly. I warmed the engine up first. Spatula skills not very good but I got it all where it needed to go because 8 hours later it started and ran for 40k more miles. Since then, JB weld is high on my list of "go to's".
