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Fixing Plastic Tank Inserts

  1. #1
    Bizarro Zoolander Petorius's Avatar
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    Fixing Plastic Tank Inserts

    I got a leak around one of the brass inserts in my KDX tank. Pulled the insert out and there is a small crack behind it. Advice on where to go from here?

    Lots of youtube videos showing people using a soldering iron, which is sketchy as hell. I dont understand how they don't go boom.

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  2. #2
    Your Father csmutty's Avatar
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    Re: Fixing Plastic Tank Inserts

    Quote Originally Posted by Petorius View Post
    I got a leak around one of the brass inserts in my KDX tank. Pulled the insert out and there is a small crack behind it. Advice on where to go from here?

    Lots of youtube videos showing people using a soldering iron, which is sketchy as hell. I dont understand how they don't go boom.
    My guess would be soldering iron temp is below ignition temperature for gasoline, yet above melting temperature of plastic?

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    -Christian LRRS/CCS HasBeen ECK Racing
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  3. #3
    Bizarro Zoolander Petorius's Avatar
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    Re: Fixing Plastic Tank Inserts

    I've been experimenting on a scrap handguard from the same bike. A heat gun is enough to get it melty. Still seems sketchy AF. Wondering if I should just use epoxy or something.

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  4. #4
    Powered by Kurtz theducman's Avatar
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    Re: Fixing Plastic Tank Inserts

    Sell you my purple kdx tank lol

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    Ducati/MV Agusta/Kawasaki/Beta
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  5. #5
    Bizarro Zoolander Petorius's Avatar
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    Re: Fixing Plastic Tank Inserts

    Quote Originally Posted by theducman View Post
    Sell you my purple kdx tank lol
    It'd probably sell faster as is, lol

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  6. #6
    Powered by Kurtz theducman's Avatar
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    Re: Fixing Plastic Tank Inserts

    I just bought a kdx, has the awesome 90's purple accents

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    Ducati/MV Agusta/Kawasaki/Beta
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  7. #7
    Lifer jasnmar's Avatar
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    Re: Fixing Plastic Tank Inserts

    The key is managing the vapors.


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  8. #8
    Lifer Tekime's Avatar
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    Re: Fixing Plastic Tank Inserts

    Empty the tank then melt? My limited experience with fuel & sealants/patches/etc is that it's impossible to get a good bond if there is fuel present - if it's clean bare plastic you might have luck with clearweld or something like that. But yeah, just melting some new plastic in sounds easier.

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  9. #9
    Lifer Kurlon's Avatar
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    Re: Fixing Plastic Tank Inserts

    Quote Originally Posted by Petorius View Post
    I've been experimenting on a scrap handguard from the same bike. A heat gun is enough to get it melty. Still seems sketchy AF. Wondering if I should just use epoxy or something.
    I should show you the redone front fender I did for my sumo, filled the prior mounting holes, drilled new ones.

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  10. #10
    Bizarro Zoolander Petorius's Avatar
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    Re: Fixing Plastic Tank Inserts

    Jason's video was too long for me to actually watch and comprehend so I just gave it a rinse, filled it with water and went at it with the heat gun. Not leaking anymore, but I overcooked it and it's kind of ugly now.

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  11. #11
    Expert Agitator GearHd6's Avatar
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    Re: Fixing Plastic Tank Inserts

    You're not going to get any sort of explosion by melting with a soldering iron. I've done light MIG welding on metal tanks and haven't had explosions. I have done more extensive welding on tanks and had some flames shoot out the open fuel fill. I had rinsed them out multiple times with water though to try and remove most of the gas and vapors. If you can leave it open to vent for at least a day you'll be that much safer.

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