Difference between revisions of "Tank Plastics Repair"

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Hi.  Been lurking for several weeks after buying a 2013 S.  Both this forum and the Unofficial Wiki have been a great resource, and wanted to (slowly) start contributing by documenting some of the mods I've been doing.  First up is an option for putting the tank plastics back together for anyone who has a similar need. I had elected to spray the plastics with automotive grade 2K paint and didn't want tape lines by the tank.  In my haste I dremel'ed off the plastic rivets without really thinking through how to put it back together.  I'm glad to report there is a pretty simple method, as summarized below:
+
This is an option for putting the tank plastics back together, given that they were separated for say painting or other process.
  
 
;Tools
 
;Tools
 +
:[[File:zeroTankRepair_01.jpg|none|300px|Tools]]
 
# towel/soft working surface
 
# towel/soft working surface
 
# tape measure
 
# tape measure
Line 12: Line 13:
 
# Clean up the plastic rivet heads so they'll smoothly interface with the plastic clamshells again.
 
# Clean up the plastic rivet heads so they'll smoothly interface with the plastic clamshells again.
 
#: Do a dry fit-check before proceeding.
 
#: Do a dry fit-check before proceeding.
# You will want approximately 1/2" x 24" of the double sided tape.
+
 
#: The Scotch stuff referenced previously is 1" wide, so I further cut the strip lengthwise to get two 1/2" strips.
 
 
# Clean the plastics thoroughly with isopropyl alcohol or soap/water.
 
# Clean the plastics thoroughly with isopropyl alcohol or soap/water.
 +
#: [[File:zeroTankRepair_02.jpg|none|300px|cleaned]]
 
# Place the tape along the ridge on the plastic.
 
# Place the tape along the ridge on the plastic.
#: You'll have to do a little trimming near the left-most lip so it follows the ridge and make a relief cut near the right-hand-side so it'll make the sharp turn.
+
#: Cut approximately 1/2" x 24" of the double sided tape.
 +
#: The Scotch stuff referenced is 1" wide; further cut the strip lengthwise to get two 1/2" strips.
 +
#: [[File:zeroTankRepair_03.jpg|none|300px|Tape laid out]]
 +
#: Trim near the left-most lip so it follows the ridge and make a relief cut near the right-hand-side so it'll make the sharp turn.
 +
#: [[File:zeroTankRepair_04.jpg|none|300px|Trimmed]]
 
# Poke or cut holes where the rivet heads used to go.
 
# Poke or cut holes where the rivet heads used to go.
# Simply remove the tape liner and firmly press the plastic and center section together for about 30 seconds each side.
+
#: [[File:zeroTankRepair_05.jpg|none|300px|Holes for the rivet heads]]
 +
# Remove the tape liner, and firmly press the plastic and center section together for about 30 seconds each side.
 
#: Due to the thickness of the Scotch tape there is a ~1/8" gap between the plastic and center section, but it's very consistent and rigid.
 
#: Due to the thickness of the Scotch tape there is a ~1/8" gap between the plastic and center section, but it's very consistent and rigid.
#: Shown in this image is the gap near the front of the tank.
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#: [[File:zeroTankRepair_06.jpg|none|300px|The gap near the front of the tank]]
#: Due to its consistency I actually prefer the look over OEM.
+
#: [[File:zeroTankRepair_07.jpg|none|300px|This is near the backside of the tank.  Same size gap, but still very consistent.]]
#: This is near the backside of the tank.  Same size gap, but still very consistent.
 
  
 
;References
 
;References

Latest revision as of 04:12, 7 November 2019

This is an option for putting the tank plastics back together, given that they were separated for say painting or other process.

Tools
Tools
  1. towel/soft working surface
  2. tape measure
  3. screwdriver/awl/something to poke 1/4" holes
  4. scissors
  5. cutting blade
  6. double-sided tape (recommend Scotch Outdoor Mounting Tape, 1" wide)
Steps
  1. Clean up the plastic rivet heads so they'll smoothly interface with the plastic clamshells again.
    Do a dry fit-check before proceeding.
  1. Clean the plastics thoroughly with isopropyl alcohol or soap/water.
    cleaned
  2. Place the tape along the ridge on the plastic.
    Cut approximately 1/2" x 24" of the double sided tape.
    The Scotch stuff referenced is 1" wide; further cut the strip lengthwise to get two 1/2" strips.
    Tape laid out
    Trim near the left-most lip so it follows the ridge and make a relief cut near the right-hand-side so it'll make the sharp turn.
    Trimmed
  3. Poke or cut holes where the rivet heads used to go.
    Holes for the rivet heads
  4. Remove the tape liner, and firmly press the plastic and center section together for about 30 seconds each side.
    Due to the thickness of the Scotch tape there is a ~1/8" gap between the plastic and center section, but it's very consistent and rigid.
    The gap near the front of the tank
    This is near the backside of the tank.  Same size gap, but still very consistent.
References
Repair Guide: Tank Plastic Clamshell Repair on EMF.