Clarke oversize tank repair

Discussion in 'The Garage' started by bigtrailie, Mar 8, 2010.

  1. bigtrailie

    bigtrailie Pursuing happiness

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    I got ripped off on Flea-bay. When the fuel tank arrived I was more concerned about how it would fit on the KTM 520 exc than with the general condition of the tank itself.

    Once I removed the filler cap, I noticed the grey RTV sealant around the base of the filler neck. I filled the tank with water and my fears were confirmed -- the "patch" is not watertight. After removing the sealant, I can now see a crack (void) that goes about half way around the circumference of the filler neck.

    Has anyone found a fix for patching up these plastic tanks? I'm guessing that RTV sealant is not the way to go. Anyone out there with successful epoxy experience???:ear
    #1
  2. Motomedic

    Motomedic Long timer

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    plastic welding is probably a better solution...
    #2
  3. ColoradoKen

    ColoradoKen Orange Cult Convert

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    If it's fixable ... welding is absolutely the way go. That class of plastic typically doesn't "glue" easily/well (or at all ??) and the location at the filler neck doesn't help matters.

    Hope you can repair it without too much expense. Don't know what to expect re. cost to plastic weld it ?
    #3
  4. Beezer

    Beezer Long timer

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    Yep, plastic weld. A good auto paint store might be helpful... they generally sell the equipment, or at least the various filler rods. If that doesn't work there might be another way, but it won't look pretty. RTV will not withstand constant contact with fuel, but this stuff will.

    Aircraft fuel tank sealer by DeSoto... the 1/2 is the working time (1/2 hour).
    PRC 1422B 1/2

    Or ProSeal...

    http://www.aircraftspruce.com/catalog/appages/prosealant.php

    edit... Another thought - you might contact the RV dealers, RVs have plastic water & waste tanks that are always gettin hit, they might advise on a reliable repair shop
    #4
  5. saddlsor

    saddlsor my butt hurts

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    I have a place on my clarke tank that I used jb weld to seal. its been on there for 4 years now. I used some 50 grit sandpaper to roughen it up to help it stick. its a cheap repair and if it doesn't work you can always try something else.
    #5
  6. scooteraug02

    scooteraug02 Dog Rancher

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    #6
  7. The Dirty One

    The Dirty One Been here awhile

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    definitely the best option here. that type plastic can be welded without filler rod if all the pieces are still there and it sounds like yours are,just cracked.

    ps
    you can use a heat gun and a regular soldering irion in most cases to do this.
    #7
  8. junglemototours

    junglemototours trailplug

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    Do you have to take the gas out?
    #8
  9. junglemototours

    junglemototours trailplug

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    [​IMG]
    #9
  10. Lesharoturbo

    Lesharoturbo Nerdly Adventurer

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    Yes. I would take the gas out. A heat gun or soldering iron work at temperatures of 400°F and up. Some of the hot air welders we have at work will generate heat >1000°F. If nothing else, this will cause the gas to vaporize and increase the pressure at the weld point. Drain the gas and leave the cap off while welding.
    #10
  11. lifer

    lifer Been here awhile

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    I had a leak in my skid loaders fuel tank about 10 years ago. It is plastic also. I went to an auto parts store and they had a plastic fuel tank repair kit. I used it and it has not leaked since. I will say the leaks were from the bolts rubbing on the tank so the holes were not real large but it worked like a charm. Personally I would open a dispute with ebay to get the guy to give back your money if it were me. You will probably have to pay to have the tank shipped back to him though.
    #11
  12. mcma111

    mcma111 Long timer

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    Wake up guys. This thread is from March, 2010.
    #12
  13. baloneyskin daddy

    baloneyskin daddy bikaholic

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    What year is it now?:rofl
    #13
  14. Lesharoturbo

    Lesharoturbo Nerdly Adventurer

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    Yeah, but the guy with a branch in his tank is from 2012. That is more recent....
    #14
  15. junglemototours

    junglemototours trailplug

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    It was a joke....taking the gas out, not the trail plug.

    Enduroshack and Clarke both stepped up and gave me a new tank, all good. Now if I can just quit putting holes in my bikes.
    #15
  16. junglemototours

    junglemototours trailplug

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    Ok, this joke is no longer funny.
    Drive 1000 miles to Idaho with a new tank, thought about bringing the stock tank as a backup....
    2 1/2 days into riding, I notice a pin hole leak, WTF! It was fine the day before :eek1
    Looked like an air bubble in the casting process finally gave up the film that must have been holding the gas in?
    Trail plug #2
    [​IMG]

    Enduroshack came through and refunded my money, the guy at Clarke was an arse.
    #16
  17. AteamNM

    AteamNM Wonna Be ADVrider

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    I started to read this thread a bit since my buddy just bought a 2006 low mileage DR 650 off CR in Austin . He finds a small weep in the arch of the inside where the mount on the frame down tube has wore it down where it sort of vapor leaks, condenses to a drip, leak. Imagine that in Texas? Then it dawned on me. PTEX, what I use to repair the plastic base on ski bottoms. Find a local ski store and call and ask if they have PTEX base repair sticks. I use a torch to finally get the PTEX to start driping and burning and then drip it on the repair area. Then you go back and of course scrap scrap scrap. Maybe use sand paper. But glob that stuff on, maybe practice a bit on some old plastic.

    If in dout, google it or ask a ski tech to show you how it works.
    #17
  18. miguelitro

    miguelitro Chuchaqui

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    sounds rediculous but if its just to get you out of the back country take your bar of soap and jam some in the crack while gas is leaking and it will seal temporarily.
    mike
    #18
  19. Kaiserktm

    Kaiserktm n00b

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    I have had decent luck using a soldering iron and "smearing" the crack back together.
    #19