Plastic gas tanks are in high demand among motorcycle and ATV enthusiasts. A plastic gas tank can weigh less than half as much as a comparable metal gas tank, and it is simple to shape to fit odd configurations. Seamless gas tanks rarely leak and are resistant to the rust and corrosion that can occur in metal tanks. If a plastic fuel tank develops small holes or tears, there are several relatively simple ways to repair it.
Method 1 Seal Plastic Gas Tank with Epoxy Glue
1. Allow the gasoline to drain and dry in the tank. Sand the area around the hole or crack and clean it with a rubbing alcohol-soaked shop cloth.
2. Apply the two-part epoxy all around the perimeter of the opening. Cut and overlap a fibreglass patch large enough to cover the opening.
3. Cover the hole with the fibreglass patch and press it into the epoxy. More epoxy should be applied to the patch and surrounding area, pressing firmly to saturate the patch.
4. Allow to dry before sanding the patched area smooth and spray painting with plastic paint, if desired.
Method 2 Seal Plastic Gas Tank with a Plastic Welder
1. Purchase or rent a plastic welder. Tell the salesperson what you intend to do with it so that you get the right rods.
2. Remove the vehicle’s plastic gas tank and place it in a safe welding area. Allow the gasoline to drain from the tank and dry both inside and out. Wear safety glasses, a welding helmet, and welding gloves.
3. Fill in the crack or hole with a plastic welding rod made specifically for this purpose. Begin at one edge and work your way around the opening. Then start crossing over the hole, allowing the rod to completely fill it in.
4. Allow the weld to cure before sanding it smooth and, if desired, spray painting it with plastic spray paint.
5. Replace the repaired plastic fuel tank on the vehicle.
Method 3 Seal Plastic Gas Tank with a Soldering Gun
1. Drain the gas tank and thoroughly clean it both inside and out with soapy water. Lightly sand the perimeter of the repaired area.
2. Cut a plastic patch slightly larger than the hole to be repaired from a similar material to the gas tank.
3. To make a trench, heat up an electric soldering gun and drag it around the edge of the crack. To push the plastic back into the trench, move the gun from side to side. Lay the plastic patch over the area while the plastic is still soft from the soldering. Continue to move the soldering gun over the area to smooth it out and fuse the plastics together.
4. Allow to completely cool and dry. Cover the entire patch with a two-part epoxy glue mixture. Allow to dry before sanding and applying a coat of plastic paint if desired.
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