These images show the damage to the tank caused by a tree stump while the excavator was working in a forestry. The stump knocked off a metal block which was attached to the tank causing all the fuel to leak out. The cross marks and scuffing are from a previously failed attempt by the owner to bond a patch over the damaged area. | Diesel Fuel Tank on a Kubota Midi Excavator
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The cost of a new tank was over £750 and was not readily available. It was successfully repaired for £80 thus making a huge saving for its owner and ensuring that the excavator was back working without delay. |
Plastic diesel fuel tanks are made from PE and it is impossible to successfully bond anything to its surface. Plastic welding is the only solution for this type of repair. |
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These plastic gutter angles were fabricated for a building which required a non-standard angle to complete the guttering around bay windows. If you need custom gutter angles fabricated, use our Contact Us page to send a message. |
Plastic Welded Gutter Angles |
Plastic gutter angles are only available in a small number of standard angles and plastic welding fabrication is the only feasible solution when a non-standard angle is required. |
Typical accident damage to bike fairings. Most bike fairings are made from ABS which lends itself very well to repair by plastic welding. The broken parts are realigned, and clamped where necessary, before plastic welding can be done. A broken flange had been used to join together the two halves of the fairing from a previous accident. |
Cracked fairings on a Suzuki SV650S |
All the cracks have been plastic welded on both sides and the fairings are now ready for refinishing.
The reverse side of the cracks have been reinforced by plastic welding strips across the line of the cracks.
The flange has been welded back in its original position. |
A replacement tank was very expensive and would not be removed easily. |
Split Water Tank on a 1997 Moody 40 Yacht |
The yacht was back at sea within hours and with minimum cost to the owner. |
This telehandler collided with a gate post and severely damaged its plastic fuel tank. The tank walls were carefully realigned ready for plastic welding. |
Repair to John Deere 3200 telehandler |
The tank was ripped open for about 60cm and the tank walls were badly distorted.
The repaired item now ready to be re-installed in the machine. A new replacement tank was not available.
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This tank was used to supply water for hand cleaning to the toilet facilities on the coach. The company wanted to modify the coach steps to accomodate wheelchairs. This required the water tank to be halved in size to make room for the modification. |
Modification to Coach Water Tank |
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The tank was split for about 250mm along the manufacturer's original welded seam. The split is not easily seen here but was immediately apparent when the tank was being filled with oil. The crack has been welded and built up along its length and a number of cross welds added across the split. |
Split in Central Heating Oil Tank |
The first stage was to clean the damaged area and "V" groove the split along its length in preparation for welding. The finished tank is now ready for refilling, having being repaired at a fraction of the cost of a replacement tank. |
This is a custom made corner lamp bracket fabricated by plastic welding. The old metal bracket had corroded but no such problems with a plastic bracket. |
Custom made corner lamp bracket |
The bracket was made from pieces of 10mm thick HDPE Black sheet plastic welded together to form the bracket. The plastic material is UV stabilised so this bracket will remain trouble free for many many years. |
This is a custom made enclosure to house a 3 phase inverter in a workshop. Because of the depth of the equipment inside, a standard enclosure was far too large and expensive. | Custom made electrical enclosure |
The enclosure was fabricated by plastic welding together sections of 10mm thick HDPE black sheet. For clarity the enclosure is shown without its clear Perspex front. |
These plastic mouldings are part of a neck brace mechanism used in cattle crushes. A cattle crush is a specialised enclosure for holding animals securely during animal welfare tasks. |
Modification to plastic mouldings |
The original mouldings (shown on the left) were too tall and needed to be shortened. This was achieved by cutting off the top section and plastic welding a new top profile. |
This is a bird nesting box fabricated by plastic welding from 10mm thick black food grade HDPE. This material is UV stabilised so will not deteriorate in the elements. This box will outlast many many times boxes made from wood and thin plastic mouldings. It has a detachable roof and drain holes in the base. |
Plastic Bird Nesting Box |
The box is very robust and completely made from plastic so will not deteriorate. Easily cleaned and never needs painting or preservatives so much healthier for the birds. It has been constructed to dimensions recommended on the RSPB website http://www.rspb.org.uk/ |
The hole in the tank was where the original fuel outlet fitting had pulled out. The black marks and square outline is where a previously failed attempt had been made to apply a patch over the hole. Trying to bond a patch on a HDPE tank is futile and the only remedy is to plastic weld a patch over the area. |
Hole in a 3ton Dumper Diesel Fuel Tank |
The area around the hole was carefully cleaned up and a new patch of HDPE plastic was plastic welded over the hole. The tank is now ready to be refitted to the dumper. This repair got the dumper back out working with the minimum of downtime and without the need to buy an expensive replacement tank. |
A piece of the fairing has broken off this Ducati 916 Desmoquattro side panel. A repair had to be done or a replacement found as the fairing was fixed to the frame at this point. |
Broken fairing on a Ducati 916 Desmoquattro |
The broken piece has been securely plastic welded on the front side and also reinforced on the rear with more plastic welding. This section has to be made very secure because the fairing is attached to the bike frame using a bolt through the hole shown. |
The customer wanted the black fairing repaired. The bottom sections had broken off and been lost so a donor fairing (on the left) was used to replace them. A repair had to be done accurately to maintain the hole fixing centres of the fairing. |
Broken fairing on a Suzuki RG500 |
The broken pieces were securely plastic welded on the front side and also reinforced on the rear with more plastic welding. Other cracked areas on the fairing were also repaired. |
This fairing had a number of cracks and also two missing lugs. |
Repair to the fairing on a Yamaha YZF750 |
The cracks were repaired and new lugs were created by building up the missing areas with plastic welding. |
This is the receiver part of an expensive Leica laser level for reading levels in building and civil engineering work. The staff had been dropped and caused the mounting bracket to crack. The rear mounting of the receiver level body was also damaged and had numerous cracks around the brass securing nut (the cracks are not easily seen in the image). |
Broken casing & fixing bracket on a Leica Laser Level |
This is clamped to the staff and gives a visual and audible signal when used in conjunction with the rotating laser beam. This is the bracket after the crack had been plastic welded. All the cracks have been very carefully plastic welded due to their proximity to the digital display. |
This is an underside view of a waste water tank from a Possl 2-Win Motorhome. The motorhome struck a raised drain cover on a driveway and ripped a large hole in the tank. |
Badly damaged waste water tank from a motorhome |
There was some distortion of the tank and on the detached part. This was straightened out and the section was successfully plastic welded back in position. |
This is a water tank typically used on a farm to provide drinking water for the livestock. A tractor had collided with the tank and split the corner in two places. |
Split Livestock Water Tank |
The corner of the tank was distorted and prior to welding the shape of the corner had to be restored. The cracks have been plastic welded and the tank is now ready to be returned to the field. |
This is a Balmoral 5455 litre potable water storage tank, 2m diameter and 2m high. While moving the tank using a forktruck the tank was punctured near the bottom by the forks, producing a split about 15cm long. The forks penetrated and distorted the tank wall and this was straightened before plastic welding the split. |
Split in a Balmoral Water Storage Tank |
Fortunately, the tank had a wide inspection hatch at the top so the split was plastic welded on the inside of the tank as shown here. Water tanks are usually made from High Density Polyethelene (HDPE) which is readily plastic welded. This is the finished repair seen from the outside. We regularly see attempts to apply patches to damaged PE tanks. These always fail because nothing will permanently stick to PE and plastic welding is the only solution for this type of repair. |
Another example of using a simple plastic welded fabrication instead of a metal welded bracket. A simple fabricated bracket solves this problem. |
Plastic brackets for securing bins to wall |
Wheelie bins regularly blow over and spill their contents everywhere. A plastic bracket is easily fabricated, very strong and never needs any maintenance. |
This was a new kayak that fell off the roof rack as the owner was removing it. Many kayaks are made from PE which is cross linked during its manufacture which means it cannot be plastic welded. See our FAQ for more details. |
Repair to Kayak after falling from roof rack |
The nose of the kayak was badly cracked. However, this one was made from standard PE which was not cross linked and was successfully repaired. |
This boat had a hole punched in its side by being thrown agaisnt a wall in a storm. The boat was made from LDPE (Low Density Polyethylene) which meant it could be repaired by plastic welding. |
Repair to Rigiflex 3.7m boat |
Luckily the owner managed to retrieve the broken piece, without which the repair would have been much more difficult. |