Onex Fuel Cap/Fresh Air Quandary ...?
Making a vent hole in the fuel cover is not the way to proceed.
The plastic vents in the windscreen (like the factory Onex) is a better option. If you do that than you need to remove the Lexan windscreen and lay it flat on a table and cut the holes with a "hole saw".
Another option (and a better one long term) is to install a Naca vent that feeds an "eyeball vent" in the cockpit. On the ground I have my 2"vent wide open but at cruise I have it closed down to half because it blows so much air.
I understand you have already painted the airplane. If you work carefully, you will be able to cut out the odd shaped hole for the Naca vent in the side skin without damaging the paint. If you want to email me I can give you more details on how to do that and some photos to show my installation.
Note: I would highly recommend to do this job that you remove the windshield, glare shield and fuel tank. Mine can all be removed in 20 minutes........then you have easy access to do this upgrade.
gdbaxter78@gmail.comGordon.........Hummel 2400.......Onex #0024