Working on Hustler 60" Model 934778....
Need suggestions for repairing plastic fuel tank. I haven't seen the leaking area but according to the owner its about middle level tank.
Been my experience that no tape or glue works on plastic gas tanks. I think most are made of polyethylene which seems to not let anything stick to it. Some glues or epoxies won't expand/contract the same as the tank and will just pop right off when there is a temperature change.
I've been trying out plastic welding on several items with some success although I've never been able to exactly reproduce the finish look without bondo/primer/paint. I have a small welder that looks like a 2 barrel electric soldering gun that uses wire that you press into the plastic. The hot wire melts into the plastic and is more for reinforcing where some strength is needed. You might be able to just use a pencil style soldering tool with the tip inserted backwards to melt and smooth out the crack that might seal up the crack. You can use a filler (like tig welding) but I think you would need to match the type of plastic. Mixing ABS, PVC, Poly, PEX, nylon or any number plastics probably won't work well. I've seen some use zip ties as a filler. Of course don't try this on a tank with gas or vapors in it.
IMO, best bet is a new tank but are they even available. The customer can't blame you if it fails. I've searched for some parts only find out they were poorly designed and the entire supply of replacements has already been snapped up.
Plastic weld it. Very simple. Can use a simple soldering iron and zip ties for rod. They make plastic welding kits you can get for cheap. I've repaired several trimmers and two backpack blower tanks. Have fuel in them year round for what 5 plus years now. No leaks so far. Got tired of buying new tanks.
#6
ILENGINE
The clear/white plastic tanks a hot glue gun will stick and seal the leak and gas will not soften it.
#7
StarTech
Also make sure the operator is not over filling the tank. The venting system will leak if the tank is above the bottom of the filler neck. Most operator never read the owners manual.
Also make sure the operator is not over filling the tank. The venting system will leak if the tank is above the bottom of the filler neck. Most operator never read the owners manual. View attachment 70634
Also make sure the operator is not over filling the tank. The venting system will leak if the tank is above the bottom of the filler neck. Most operator never read the owners manual. View attachment 70634
Also make sure the operator is not over filling the tank. The venting system will leak if the tank is above the bottom of the filler neck. Most operator never read the owners manual. View attachment 70634
The last 2 I have repaired, I have used a left over older plastic/abs tank. I cut a small strip, from the tank to melt back over the damaged spot. I clean the spot, and about 2 inches around the area to be repaired. Rough it up with a clean wire brush and or very coarse sandpaper.
I then clean again with acetone and use my soldering gun with a wide flat tip, first melting or “fusing” the tank split/hole to itself, then melt in the other strip removed from the old discarded tank as a weld patch, pushing the melting strip slightly into the surface of the tank working further away from where you started, basically for strength. If you don’t have an old tank to get a strip out of, I’m sure any small engine repair shop will have one they’ve tossed out. Of course if it’s a small pin hole of some sort and on a flat surface, the old way I fixed metal tanks by using a small stainless steel sheet metal screw with a silicone o-ring is a great fast fix. Use extreme caution as it’s the gas fumes that just needs a spark. All of the above is how I repair, and in no way am I stating you or anyone else should use this way to do yours.
Working on Hustler 60" Model 934778....
Need suggestions for repairing plastic fuel tank. I haven't seen the leaking area but according to the owner its about middle level tank.
Assuming it's plastic, not metal.
I've plastic welded several of the PLASTIC gas tanks including the large rear mounted ones. I get best results if I can remove a piece of plastic from the tank I'm welding to use as a filler, but I've used milk cartons and zip ties as a filler.
I use a large 120volt soldering iron. and weld the plastic patch into the tank.
After welding and before re-installing I use soap and water to check for good seal by plugging the fuel line outlet and just use a rag around the fill spout hole and a air gun. This will give about one -2 psi. Too much air pressure can easily cause the seams to separate, etc.
On the large rear mounted tanks on lawn mowers make sure the tank is properly mounted and cushioned when re-installing and not being warped.
Most generally if it's about 1/2 way up on a large tank it the seam of the two halves and quite common. Some of the large plastic tanks are both expensive and or NLA.
You can go on You tube and get some ideas about plastic welding.
Flush the tank good with water before starting.
I purchased a HF plastic welder and I use the black zip ties for the black abs tank welds and the white zip ties for the white or clear tanks with great success. I also purchased the heat stitch tool that uses metal staples that you heat up and press into the larger cracks to give added strength to the repair. Of course I have drain the gas tanks of fuel and flushed with water to remove any fumes before attempting these repairs. Do not rush the repairs as going slow and making sure the heat has penetrated the area as well as the filler material will assure a quality repair every time.
And the IPL shows it venting via a fuel filter straight to the ground or least that how a local Hustler is setup. And it uses a four way connector it makes sense that a fourth line would go to the intake.
Working on Hustler 60" Model 934778....
Need suggestions for repairing plastic fuel tank. I haven't seen the leaking area but according to the owner its about middle level tank.
The area on the side of the tank you can see the fuel level from the outside of the fender had numerous cracks. I got a plastic welding kit and with suggestion from forum members was able to seal them up.
