Field Hack - Plastic Welding Repairing a Gas Tank

We repair a crack in a fuel tank using a common plug in soldering iron.
This tank was repaired filled with fuel and ridden immediately after the repair without any leaks.
What field plastic repairs have you made with the hot weld method?

[@race5050R1]

I plastic welded my 1991 KX250 tank near the petcock around 30 years ago and it held until now. It’s leaking again from same place so time to redo the repair. Great video! Thanks!

[@devintrachsel9950]

Thanks man, from your video you saved be from buying a new gas tank for my bike.👍

[@TACOMOTOCO]

Nice

[@damianstasek8946]

You are the best Mike!

[@jeffro7p202]

Milwaukee makes a really nice 12v cordless soldering iron. Even has a 5 year warranty.

[@frankneikes]

Thanx Mike you always come good ! Just broke my tank and was wondering how to fix it ! Got the tank in the hostel ! Hope they don't mind me going with heat on a fuel tank! If your wandering I emptied it before ! Let's hope mine looks as good as yours

[@bajamcguide]

Awesome job, thanks for sharing

[@profesonalantagonist]

A soldering iron might work as a field fix, but it will be subpar at best. It is hard to use a soldering iron without burning the plastic. Plastic welding HDPE or LDPE, which is what tanks are made of, requires a temperature of 450* , your soldering iron is typically 750*. The soldering iron will burn the plastic making it dirty and unable to weld. Sure it can be done with a soldering iron, but it will be difficult and likely leak. A Laramy or other brand hot air welder is the proper tool. Even Harbor freight sells plastic welders, the air welder kind and a soldering iron style that that stops at 525* a little high, but better than 750* ! Also get some proper HDPE and LDPE weld rods for filler, donor plastic is not always easy to find, and who wants to cut strips off their fender? Also get a Dremel with a cone shaped burr for cleaning and grinding the weld. Don’t let your cracked gas tank be your first repair ! Get the kit and practice on an old used tank, it is not easy but a valuable skill to learn !

[@veronly2]

a ts100 or the usb-c version of it may make good work of this

[@MakeFixUpgrade]

In a pinch I've used melted zip ties to fix plastic cracks. I always carry a few out on rides.

[@chasejiannalone8763]

Not sure if you mentioned this, but you could get it back in the shop and sand it and then polish the repair. Never get it looking new but maybe closer to new than the rough repair finish you have there. .

[@bankayhoodlum]

Awesome 😁 IME, melt repairs tend to be brittle and thus less strong so be careful in parts that flex.

[@TACOMOTOCO]

Well noted

[@beaud4474]

I would be tempted to try a magnifying glass . Less mucking and super focused heat maybe . Tough to do at night.

[@davenawahine4428]

Pretty sure ptex would work good as a filler since its the same material as gas tanks. The good thing about ptex is you light the end and let it drip into the crack or hole. It bonds as it cools. All though fumes might be an issue.

[@rfiskillingussoftly6568]

Honestly, did the fix last? I'm asking cuz I have a crack in my tank! Where did you get the plastic from and how were you sure that you had the right plastic to weld with? Thanks man!

[@jwayne777]

Awesome. This is a zombie apocalypse repair.

[@Mohapi_Tau]

Is the itself tank made of metal or plastic?

[@lopsided1]

Makes me want to get a USB soldering iron since I already have USB ports

[@jupitermaramba2527]

Honestly,. Did this holdup long term?

[@bobfitzsimmons3257]

Feeding donor material strips through a hot glue gun may give you better filler flow.

[@newenglandscrambler2262]

Mike, what about using epoxy instead in a pinch? I usually carry some with me.

[@TACOMOTOCO]

We’ve never had it work for us on a fuel tank but you may have better luck

[@bobbybrown4652]

Beautiful, i like that a lot :)

[@carlosgraphic]

Have somebody tried to use melt plastic in this kind of Job? Just saying, if melt plastic is hot enough to melt, mix and seal de hole?

[@KC-GOD-IS.]

The key is to have a METAL fuel tank.

[@TACOMOTOCO]

Or stay home on the couch. Much safer