Help ! 2008 GSA Fuel Tank Frustrations...

[Scotriders]

My two pence worth.
Use a rotary burr in a Dremel ( Lidl do sets of fine diamond burs Very cheap). Remove the plastic around the top of the brass bushes that are rotating.........

If Carlsberg did advice on how to remove fuel filler screw inserts......

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[theoneandonly]

or screw in 2 self tappers to hold the insert.

 

[Mistacat]

As an afterthought ounce the CSK screw heads are removed along with the filler flap it would be easier to chain drill around the M5 screws with a 2mm drill bit down to the brass bush prior to using a rotary bur to finish.
Not sure if you have to Dry calibrate the aftermarket fuel strip prior to fitting as you do the OEM one, no doubt it will tell you on the instructions.

 

[Magwych]

I gave up. Second habd tank from Motorworks bypassed that issue.