Coolant expansion tank repair.

[ajlelectronics]

I have a tank with a mounting ear broken off. I cannot replace the tank, it appears that nobody has one. It is a Fiesta early tank, the Mk2 doesn't fit so need to re-use the one I have.

Looking at the job, I will need to make a custom mounting bracket, just as I would have when the mounting ear was present, so my thoughts are to make a new metal bracket and glue it to the flat bottom of the tank. Not sure what the material is, some sort of Nylon maybe?

What adhesive would give a long lasting bond? I have Epoxy resin, Polyester resin and JB weld to hand.

 

[ajlelectronics]

 

[Nick67GT]

Have you tried Harry Buckland in Staverton?

Good thing is, you can still wander around the yard and remove parts yourself. Prices are fair as well.

 

[slim_boy_fat]

That 'waxy' type plastic is a pain to glue. Araldite?

 

[Rig Pig]

It may be better to make something that straps round it like a large jubilee clip than trying to glue it.

 

[choco]

Jb weld is dam strong my favourite epoxy. The old one that takes ages to cure not the fast curing stuff

 

[The_Yellow_Ardvark]

Look at Ford escorts.
The ones of the same age use similar tanks.

They are real pain to glue.

 

[pedrobedro]

Hot melt glue gun, I did a Sierra one and it held for years.

 

[Parm]

How about a metal bracket held on to the tank with fibre glass and resin ?

 

[wristpin]

Q-Bond with the reinforcing powder to build up the joint.
Www.qbond.net

 

[octo0072000]

your not going to like it seen a split plastic tank fastened together with a metal plate and self tappers and rtv sealant didn't leak

 

[reedx]

Assuming the plastic is of a suitable type, I've had very good results with Plastex. The video shows mounting tabs being remade using the molding bars.

http://www.repairingproducts.co.uk/?s=plastex&post_type=product

Colin

 

[dobbslc]

That tank will probably be mdpe / hdpe. medium / high density polyethylene
Very hard to bond to, you can buy specialist adhesive for this stuff but was very expensive the last time I looked. It would be cheaper to buy a nice alloy one off eBay.

 

[Bill Edwards]

I'd also go with Q bond, plenty of reinforcement. It's good stuff.
I'd rough it up nicely with emery first to give it something to key onto, do it patiently in layers.

 

[ajlelectronics]

The issue is that this tank is for my project car, so anything I do needs to look engineered rather than wrapped in chicken wire and tape ;-)

If I could get a new tank I would, but the only source wants £90 for them and I am not paying that. The original tank for the 2.8 is an early Transit tank and much smaller. Also no more available that the Fiesta tank. See that in the first photo.
Second and third photos are of the Middlebridge installation from the factory.

So you see my quandary?

 

[sardine]

Weld it with a soldering iron ?

 

[hotrodder]

Why do you need an early Fiesta header tank? That's not a fiesta or an engine that was ever fitted to fiestas so why try and fix an ancient (probably brittle everywhere) broken plastic header tank that still needs brackets making to fit it to the project car?

Personally i'd make a new ally tank (less than £20ish worth of materials most of which would be for the neck) or buy a cheap plastic tank for something else that has the correct dia outlet & vent/return and make that fit

 

[steveo3002]

id rather see a good alternative than a bodged up original...you can always keep an eye open for the right one to swap over

 

[Bill Edwards]

With what you're after (i.e not a 'get it working again' patch) I would be looking to just make a new metal one instead. Surely a nicely welded purpose built tank will leave nothing to be desired?

 

[ajlelectronics]

Why do you need an early Fiesta header tank? That's not a fiesta or an engine that was ever fitted to fiestas so why try and fix an ancient (probably brittle everywhere) broken plastic header tank that still needs brackets making to fit it to the project car?

Fair comment. The reason for that particular tank is that I am trying to keep as close as realistically possible to the Middlebridge design. The GTC was the Middlebridge that just missed being produced before they went out of business. I want this one to be "that" car. However, being sensible, I have to try to use available parts rather than track down a one off that I then need to replace in the future, with the same sourcing problems.

I have been looking for a new replacement that will fit, but drawn a blank so far of something with the ports in the right place and that will fit the space. If I had acces to a dozen possibles, life would be easier, but I am having to go by pictures and descriptions.

A query... I assume that the capacity is important? With a 2.9i engine and big radiator, there will be a fair expansion, maybe I could see what it blows out and use that new level? There is a VW? globe design tank that I could use a bit closer to the front, but it isn't very big.

Something like this: