Omar Khalid
Plastic coolant fittings are prone to cracking and breaking, especially at the metal interface, which can cause the water to drain out of the car and onto the road. This can be dangerous if the engine is not stopped in time. While some people opt for quick fixes such as duct tape, zip ties, or water bottles, others suggest more permanent solutions like patching with two-part epoxy and a piece of fibreglass matte, or plastic welding. In some cases, the entire thermostat housing may need to be replaced, or a new O-ring may need to be inserted.
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What You'll Learn
Using a two-part epoxy patch kit
To repair a plastic coolant fitting using a two-part epoxy patch kit, you can follow these steps:
First, source a suitable two-part epoxy patch kit. These are available from local hardware stores or AAP stores. Ensure the epoxy is suitable for the job by checking it can bind and cure underwater—the type used to fix boat hulls is ideal. It should also come with a piece of fibreglass matte to reinforce the repair.
Before you begin, make sure the area you are repairing is clean and dry.
Once you are ready to start, mix the two parts of the epoxy together, following the kit instructions. The epoxy will get very hot as it mixes.
Apply the mixed epoxy to the crack or leak in the plastic coolant fitting, using the fibreglass matte to reinforce the repair. Follow the kit instructions for the correct application method.
Allow the epoxy to cure fully before testing the repair.
This method is capable of effective repairs if carried out carefully and correctly, as directed by the kit instructions.
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Plastic welding
To weld plastic, you must first set up your workspace. Ensure your workspace is well-ventilated, as most heating techniques emit dangerous fumes. Wear protective gear, such as gloves and eye protection. Clean the thermoplastics to ensure a high-quality weld. This can be done with soap and warm water, followed by drying with a clean, lint-free cloth. You can also use liquid solvents or sandpaper to remove any stains.
Once your workspace and materials are prepared, you can begin the welding process. Clamp and tape the two plastic pieces together to form and hold the desired joint. Place the plastic pieces on a workbench and secure them using C-clamps. If you are using a handheld hot iron welding tool, you can perform the initial tack welding to hold the pieces in place before the main welding stage. Push-fit the tacking nozzle onto the hot air tool and run the tip along the weld line, joining the two materials.
For the main welding stage, you can use the "Pendulum Welding" technique for short weld runs or difficult-to-access areas. Fit the standard nozzle onto your welding tool and set the required welding temperature. Once the tool has reached the desired temperature, select the correct welding rod and cut the tip to a point to aid the initial flow. Welding should be carried out in one continuous run along the length of the area being welded. Adjust the welding speed to create a slight "wash" or shiny spot at the sides of the welding rod.
After welding, allow the plastic to cool completely before trimming or sanding the welded joint. Sanding or using other surface finishing processes can smooth the joint and improve the overall appearance of the weld.
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Replacing the entire thermostat housing
To replace the entire thermostat housing, you will first need to drain the coolant. This can be stored and reused later. Next, remove any residue from the sealing surface and housing flanges. This step is important as any residue left behind could cause an improper fitting, leading to a coolant leak.
Then, replace the thermostat with a new one that has the same heat rating. Ensure that the valve end is pointing up and the spring side goes into the engine. It is also important that the new thermostat is correctly aligned.
After this, add coolant to the system and screw the radiator cap back on. Run the car for around 10 minutes while monitoring the coolant level. This will also help to remove air bubbles from the system.
The time it takes to replace a thermostat depends on the make of the car, but it should take a home mechanic around a couple of hours. It is a job worth doing yourself as it can be expensive to have it done at a garage.
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Duct tape as a temporary fix
Duct tape can be used as a temporary fix for a coolant leak, but it is not a long-term solution. While it may provide a quick fix, it is important to note that the pressurised system in the engine can cause the tape to fail due to the pressure and temperature. The adhesive on duct tape typically begins to loosen around 140 degrees Celsius, while your engine usually operates at temperatures between 190 and 200 degrees Celsius.
To apply duct tape as a temporary patch, ensure that the surface around the leak is clean and dry. Cut a piece of duct tape large enough to cover the leak and extend beyond it on all sides. Remove the backing and firmly press the tape over the leak, smoothing out any air bubbles. For added security, wrap the tape several times around the leak, creating a thick coating. You can also use electrical tape, which is designed to withstand higher temperatures.
It is important to note that this solution is only temporary, and you should replace the coolant reservoir or repair it permanently as soon as possible. A more permanent solution involves using a two-part epoxy with fibreglass matte, available at auto parts stores, to patch the crack. Alternatively, you can try plastic welding, where you melt similar plastic into the damaged area.
While duct tape can be a quick fix in an emergency, it is always best to address the issue properly to avoid further complications and potential engine damage.
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Zip-tying a Gatorade bottle in
One method for repairing a cracked plastic coolant reservoir is to zip-tie a Gatorade bottle in place. This can be done by following these steps:
First, purchase a 32oz Gatorade bottle from your local store. You will also need a plastic zip tie, at least 6" in length, some P-Cord or climbing accessory cord, scissors or a nail clipper, and a lighter.
Next, burn the ends of the P-Cord to create a melted bulge. Slip the zip tie loosely around the neck of the bottle and insert the P-Cord. Pull the zip tie tight around the neck, ensuring the burnt ends of the P-Cord are snug against it. You can then clip off the excess zip tie and use the lighter to smooth any sharp edges.
Now you have a durable and lightweight bottle that can be clipped to your harness or pack.
This method is a quick and easy fix, but it is worth noting that there is conflicting information about the safety of reusing plastic bottles in this way. Some people argue that if a bottle is safe to hold acidic Coke for months, then it should be safe to reuse, but others advise against it due to the potential leaching of harmful compounds into the water.
For a more permanent solution, you could consider purchasing a patch kit from your local AAP store. These kits use a two-part epoxy and a piece of fibreglass matte to create strong and effective repairs. Alternatively, you could attempt to weld plastic into the crack or take your old reservoir to a metal fab shop to get a new one welded from stainless steel, although this option is likely to be more expensive.
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Frequently asked questions
Some temporary fixes for a leaking coolant hose include using duct tape, inserting a plastic or metal pipe, or using zip ties to attach a Gatorade bottle.
You can use a two-part epoxy with fibreglass matte to patch the fitting. Ensure that the surface is clean and dry before applying the epoxy. You can also try plastic welding to melt similar plastic into the fitting.
You can find patch kits at your local hardware store or AAP store. These kits typically include a two-part epoxy and fibreglass matte.
It is important to ensure that the surface is clean and dry before applying any patches. Additionally, be cautious when removing the O-ring inside the fitting to avoid damaging it. If the fitting is threaded, it may be under permanent tension, which can cause stress cracking.
