Plastic Gas Tank Repair

I'm repairing this gas tank that has a puncture hole.
This repair should work on any fuel tank made from crosslinked polyethylene.
This specific repair is on a Yamaha WR250R oversize IMS 4.7 gallon gas tank. The manufacturer states it is made from crosslinked polyethylene (XLPE). It is very durable, but difficult to repair. Epoxies and plastic welders will not work on crosslinked PE. Melting low density polyethylene (LDPE) plastic in the hole is the only good fix I could find. LDPE is #4 on the recycling code arrows if you want to repurpose things you may have in the recycle bin.
Drain and dry your tank first!! Do not use an open flame!!
Perform this repair at your own risk, I'm not responsible if things go horribly wrong and you burst into flames.
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[@nelsonsantos770]

Thanks for the info! Thats pretty good info!

[@banjohappy]

I like the idea of using the heat gun instead of a soldering iron. Will try on my tank.

[@fromthebackofmymind]

I got the HF 80 watt iron. It came with black poly sticks. Repeated remelting and adding material chasing the blow molded parting seam. Frustration for sure. My mower is no longer made so spares are hard to find. Turns out there was a recall of the fuel tanks in 1994.
That is a day late.

[@charlesdowens]

How’s it holding up? Thanks for the video

[@peppermoongarage]

So far so good - no leaks. I feel it's a solid fix. Just don't try to melt the tank material (it will burn before it melts) and you'll be fine.

[@charlesdowens]

@@peppermoongarage that’s much appreciated sir. Thank you

[@charlesdowens]

@@peppermoongarage I’m trying to avoid taking the tank off, it’s on my vehicle and the gas tank was punctured four days ago, so I’m assuming quite a bit of the fuel has leaked out
I think I’m gonna try to melt the plastic and then stick it in there so that I don’t get the heating iron to ignite the fumes

[@derricksmith809]

Hell yeah