.............................Actual repair takes place on page 6. If you are repairing a paintable KTM 640 Adventure gas tank you may skip right to page 6. All kinds of fun info about different plastics and welding leading up to page 6. What NOT to use too................... Well S!*t, Yesterday Was FUN and hard on my bike! I went to Clear Creek Callifornia for a riding clinic and came home with a blown fork seal, a sore body, a muddy bike and worst of all, a cracked gas tank........Oh yeah, and a smile on my face that I can't wash off. Yes, I've checked the bleeping thread index and it seems to be that "plastic welding" is the best way to fix this. Can somebody point me in the direction of "how-to" plastic weld? I used to work in a ski repair shop and have a lot of experience doing "base welds" on skis and snowboards so I think I have the hands to fix it myself. Exactly what kind of materials would I need (minimum required) to do a perminant home repair? Can I build up some plastic to fill in the void space? The crack is on the tab that bolts the tank down so it's got to be strong! A step by step how to would be great. I drainded the tank last night and have been letting the fumes evaporate. Here's a shot of water flowing like gas!