Recently when I rebuilt my fan in my Indy I had to repair my Coolant overflow tank. The top tab was broken and the bottom tab cracked. I am a welder by trade so I figured I'd try my hand at plastic welding. First I watched a video on plastic welding. I should note that I used no filler rod at all, just the milk carton and a small soldering iron with a modified tip made from a sawed off flat tipped screwdriver. I cut up the milk carton and folded it into an envelope type sleeve that fit over the tab. Then sleeve was 4 folds thick (2 on either side with the tank in the middle). Then I welded tab on trimmed the edges with a bench grinder, then clamped and rewelded the edges, then drilled the hole and welded around the hole. It's best to clamp wherever the seams come together. Don't grind where you welded the seams or you'll ruin your weld. It's stronger than the original. The video suggested to melt in cut and formed pieces of paperclip around the hole to give the same reinforcement as rebar in concrete. I didn't do that because it's kind of messy looking and it's not necessary if you weld both sides around the hole. It was harder to upload this picture than to weld the plastic [url=https://www.facebook.com/photo.php?fbid=10153218289969022&set=a.10153218255719022.1073741826.671459021&type=1&theater][/url]
[This message has been edited by danscrazymodshop (edited 08-25-2015).]
