Mouse over each image to see a magnified view and use the scroll wheel to zoom in and out.


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

Damaged plastic fuel tankDamaged plastic fuel tank
Repaired plastic fuel tankRepaired plastic fuel tank

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.
     


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 welded gutter angles fabricated to your design
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

Cracked bike fairingPlastic welded bike fairing
Cracked bike fairingPlastic welded bike fairing
Cracked bike fairingPlastic welded bike fairing

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.

     


Approximately 50mm long split in the top of the water tank near to the corner of the baffle in the tank.

 

A replacement tank was very expensive and would not be removed easily.


Split Water Tank on a 1997 Moody 40 Yacht

Cracked water tank on a Moody yachtPlastic welded repair to water tank on a Moody yacht
Cracked water tank on a Moody yachtPlastic welded repair to water tank on a Moody yacht


The split has been grooved out and securely plastic welded. Then the area was built up with more plastic welding to reinforce the area over the split.

The yacht was back at sea within hours and with minimum cost to the owner.

     


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

Split in central heating tankSplit in central heating tank
Plastic welding repair to split in central heating tankPlastic welding repair to split in central heating tan

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

Plastic welded lamp bracketPlastic welded brackets made to your design

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.

  If you need a custom bracket fabricated for any application, use our Contact Us page to send a message.  
     
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

Plastic welded custom enclosurePlastic welded custom enclosure to your design
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.
  If you need a custom enclosure fabricated for any application, use our Contact Us page to send a message.  
     


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

Plastic welding modifications to plastic mouldingsPlastic welding modifications 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

Plastic welded bird nesting box will outlast many wood boxesBird nesting box made from 10mm thick HDPE with detachable roof

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

Damaged plastic fuel tankPlastic welding repair to fuel tank
Damaged plastic fuel tankPlastic welding repair to 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

Broken fairing on a Ducati 916 DesmoquattroPlastic welding repair to fairing on a Ducati 916 Desmoquattro
Plastic welding repair to fairing on a Ducati 916 DesmoquattroPlastic welding repair to 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

Broken fairing on a Ducati 916 DesmoquattroPlastic welding repair to fairing on a Ducati 916 Desmoquattro
Plastic welding repair to fairing on a Ducati 916 DesmoquattroPlastic welding repair to fairing on a Ducati 916 Desmoquattro

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

Badly damaged motorhome water tankPlastic welded repair to motorhome water tank



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

Leica laser level frontLeica laser level rear
Leica laser level cracked mounting bracketLeica laser level mounting bracket repaired by plastic welding
Leica laser level cracked bodyLeica laser level body repaired by plastic welding



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

Badly damaged motorhome water tankPlastic welded repair to motorhome water tank



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

Cracked livestock water tankCracked livestock water tank
Cracked livestock water tankPlasic welding repair to cracked 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

Balmoral Potable Water Storage TankBalmoral Potable Water Storage Tank plastic welded on the inside
Split in a Balmoral Potable Water Storage TankSplit in a Balmoral Potable Water Storage Tank
Split in a Balmoral Potable Water Storage TankPlastic welding repair to split in a Balmoral Potable 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

Plastic welded brackets for securing wheelie bins to a wallPlastic welded brackets for securing wheelie bins to a wall
Plastic welded brackets for securing wheelie bins to a wallPlastic welded brackets for securing wheelie bins to a 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

Repair to Kayak after falling from roof rackRepair to Kayak after falling from roof rack
Repair to Kayak after falling from roof rackRepair 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

Repair to Rigiflex 3.7m boatRepair to Rigiflex 3.7m boat
Repair to Rigiflex 3.7m boatRepair to Rigiflex 3.7m boat


Luckily the owner managed to retrieve the broken piece, without which the repair would have been much more difficult.