Omar Khalid
Plastic gas tanks are popular among motorcycle racing and ATV enthusiasts due to their lightweight and easy-to-shape properties. They are also seamless, leak-resistant, and impervious to rust and corrosion. While plastic gas tanks are durable, they may occasionally need to be modified or repaired. This can be done using epoxy glue and a fiberglass patch, or with a plastic welding rod. It's important to note that some repair kits, like TankWeld, are not suitable for plastic repairs. When modifying a stock plastic gas tank, consider using a 2-piece compression bulkhead fitting with a solvent-resistant rubber seal to avoid compromising the tank's strength.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Repairing small holes or tears | Drain the tank, let it dry, sand the area, clean with a cloth and rubbing alcohol, apply epoxy glue, cover with a fiberglass patch, and sand smooth |
| Repairing with a plastic welder | Drain the tank, use a plastic welding rod to fill in the hole, sand, and paint with plastic spray paint |
| Sealing the tank | Use a 2-piece compression bulkhead fitting with a solvent-resistant rubber seal or a brass fitting |
| Alternative repair kits | TankWeld, Permatex, Seal-All, Rectorseal pipe dope, or epoxy glue and fiberglass patch |
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What You'll Learn
Use epoxy glue and a fibreglass patch
To modify a plastic gas tank using epoxy glue and a fibreglass patch, you must first remove the tank from the vehicle and set it up in a secure welding area. Drain the gasoline from the tank and allow it to dry both inside and out. Put on protective eye gear, a welding helmet, and welding gloves for safety.
Next, sand the area around the hole or crack with coarse-grit sandpaper and clean it with a cloth soaked in rubbing alcohol. This will ensure that the adhesive compound can adhere properly. Mix the two-part epoxy together and apply it all around the perimeter of the opening. Cut a fibreglass patch large enough to cover the opening with some overlap.
Place the fibreglass patch over the hole, pressing it into the epoxy. You can also apply more epoxy to the patch and the surrounding area, pressing firmly to saturate the patch. Allow the epoxy to dry, then smooth out any bumps or unevenness with sandpaper. If desired, spray paint the patched area with plastic paint.
Using epoxy glue is a quick and easy way to seal a plastic fuel tank, but it may fail after a short time. For a stronger repair, consider using a plastic welding rod or a soldering gun to fill in the crack or hole. You can also use epoxy putty, which creates a permanent bond and can be drilled, filed, machined, and painted once cured.
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Welding with a plastic welding rod
Plastic gas tanks are popular among motorcycle racing and ATV enthusiasts due to their lightweight and seamless nature, which makes them impervious to rust and corrosion. When modifying or repairing a plastic gas tank, it is essential to follow specific steps to ensure a safe and effective outcome. Here is a detailed guide on welding with a plastic welding rod:
Prepare the Work Area and the Tank:
Before beginning the welding process, ensure you have a secure welding area with adequate ventilation. Remove the plastic gas tank from the vehicle and drain all gasoline from it. Allow the tank to dry thoroughly, both inside and out. Put on the necessary protective gear, including eye protection, a welding helmet, and welding gloves, to ensure your safety during the welding process.
Choose the Right Plastic Welding Rod:
Selecting the appropriate plastic welding rod is critical to the success of the weld and the strength of the joint. It is essential to use a welding rod that matches the material of the plastic gas tank. For example, if the tank is made of high-density polyethylene (HDPE), use an HDPE welding rod. The size of the welding rod also matters, as the correct rod diameter will enable you to make stronger welds. Ensure you purchase high-quality welding rods made from the highest-grade resin materials.
Welding Process:
Start by sanding the area around the hole or crack in the plastic gas tank. Clean the area with a cloth saturated with rubbing alcohol to remove any residue. If you are using a plastic welder for the first time, it is advisable to practice on a separate piece of plastic before attempting to weld the tank. Begin welding by heating the area around the crack or hole. Use the plastic welding rod to fill in the damaged area, ensuring that the rod material matches the tank material. Start at the edge of the hole and run the bead completely around the opening. Then, begin crossing over the hole, allowing the rod to fill it completely.
Finishing Touches:
Once you have filled the hole or crack with the plastic welding rod, allow the weld to cool and set. After it has hardened, you can sand the repaired area to smooth out any bumps or unevenness. If desired, you can paint the repaired area with plastic spray paint to match the colour of the gas tank. Reinstall the repaired tank into the vehicle, taking care to follow the correct procedures.
Plastic welding can be an effective way to repair or modify plastic gas tanks. However, it is important to practice and improve your technique to ensure successful and durable welds. Always follow safety precautions and choose the right welding equipment and materials for the best results.
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$19.49
Seal with a plastic welder
Plastic gas tanks are popular among motorcycle racers and ATV enthusiasts because they are lightweight and easy to mould into various shapes. Seamless plastic gas tanks are also impervious to rust and corrosion, which commonly affect metal tanks. However, plastic gas tanks can still sustain small holes or tears, which can be repaired in several simple ways.
Before using a plastic welder, ensure that you are in a secure welding area and don protective eye gear, a welding helmet, and welding gloves. It is also important to note that while a plastic welder is safe around gasoline and gasoline fumes due to its high flash point, it should not be used near open flames.
Firstly, remove the plastic gas tank from the vehicle. Then, drain the gasoline from the tank and allow it to dry both inside and out. Next, use coarse grit sandpaper to sand the area around the hole or crack. Clean the area with a cloth soaked in rubbing alcohol to remove any remaining residue.
Now, you can begin the welding process. Use a plastic welding rod designed for this purpose and start by filling in the crack or hole from the edge, running the bead completely around the opening. Then, begin crossing over the hole, allowing the rod to fill it in completely.
Once the weld has set, you can sand it smooth and, if desired, paint it with plastic spray paint. Finally, replace the repaired plastic fuel tank on the vehicle.
If you are using a plastic welder for the first time, it is recommended to practice before attempting to seal the plastic gas tank. Consult with the rental store to ensure you have the correct equipment and understand the process thoroughly.
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Seal with a soldering gun
To modify a plastic gas tank, you must first remove it from the vehicle and set it up in a secure welding area. Next, drain the gasoline from the tank and allow it to dry both inside and out. Put on protective eye gear, a welding helmet, and gloves.
If you choose to seal your plastic gas tank with a soldering gun, you should be aware that this process is actually a form of welding, not soldering. You will need to know the type of plastic your tank is made of, have more of this material on hand, and know its melting point. If you heat the plastic too much, you will burn it and significantly weaken the structure.
To weld plastic, apply heat to a thin metal strap and push it into the plastic. This will create a joint that is almost as strong as the original plastic. You can also use hot staples to repair plastic.
If you are using a plastic welder for the first time, it is recommended that you practice before attempting to seal the tank.
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Use a compression bulkhead fitting
Installing a compression bulkhead fitting in a plastic gas tank can be a straightforward process, but it's important to take certain precautions to ensure a safe and effective installation. Here's a detailed guide on how to do it:
First, assess the amount of space available under the tank when installed. This is crucial for determining the feasibility of using bulkhead fittings. Consider the potential for leaks, as well as the structural integrity of the plastic tank with bulkhead fittings.
Next, determine the appropriate size and type of bulkhead fitting for your specific tank. Common options include Earl's -10 bulkhead fittings with Teflon washers or nylon washers on both ends. Choose a fitting that suits your tank's dimensions and intended use.
Now, it's time to install the fitting. If you have access to the inside of the tank, follow these steps:
- Remove the plastic gas tank from the vehicle and set it up in a secure area.
- Drill a hole in the tank's sidewall, ensuring it's the correct size for your bulkhead fitting.
- Slide the gasket over the body of the fitting.
- Insert the fitting body into the hole from the inside of the tank.
- Apply the recommended thread tape to the fitting body.
- Install the large nut on the outside of the tank and hand-tighten it, plus an additional quarter turn with a wrench.
- Inspect the gasket for any creep. If there is creep, loosen the nut and repeat steps 4 and 5.
- Conduct a 24-hour hydro test before using the tank to test the gasket seals and fittings.
If you only have access to the outside of the tank, follow these modified steps:
- Drill a hole in the top of the tank that is large enough to pass the bulkhead fitting through.
- Run a stiff wire (such as baling wire) from the hole at the top to the hole you drilled in the side of the tank.
- Thread the bulkhead fitting onto the wire, nut-end first, and don't forget to include the gasket.
- Slide the bulkhead fitting down the wire until it reaches the hole.
- Use needle-nose pliers to gently grab and pull the fitting through the hole.
- Once the fitting is in place, tighten the nut. If needed, use a wrench and protect the threads with cardboard or a rag to avoid damage.
- Conduct a 24-hour hydro test before using the tank to ensure the gasket seals and fittings are secure.
Remember, it's important to consult the B.O.S.S. Fitting Assembly manual and installation guides for specific torque wrench tightening settings and other detailed instructions. Additionally, always prioritize safety and follow recommended practices for working with fuel systems and plastic gas tanks.
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Frequently asked questions
To modify a plastic gas tank using epoxy glue, start by draining the tank and letting it dry. Sand the area around the hole or crack with coarse grit sandpaper, and clean it with a cloth soaked in rubbing alcohol. Next, mix the epoxy glue, apply it over the opening, and press a fiberglass patch over the epoxy. Let the epoxy dry, then smooth out any bumps or unevenness with sandpaper, and spray paint with plastic paint if desired.
Remove the plastic gas tank from the vehicle and set it up in a secure welding area. Drain the gasoline from the tank and allow it to dry both inside and outside. Put on protective eye gear, a welding helmet, and welding gloves. Use a plastic welding rod to fill in the crack or hole. Start at an edge and run the bead completely around the opening, then begin crossing over the hole, allowing the rod to fill it in completely. Allow the weld to set, sand it smooth, and paint it with plastic spray paint if desired.
Some alternative methods to modify a plastic gas tank include using a plastic welder or a soldering gun. You can also use a 2-piece compression bulkhead fitting with a solvent-resistant rubber seal. Additionally, you can use yellow Teflon tape or yellow rectorseal pipe dope, which is rated for compressed fuel gases like natural gas and propane.
