1999 Fuel Tank Repair TBD - Saab 9-5 Bulletin Board - Saabnet.com
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1999 Fuel Tank Repair TBD
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Posted by K.Daehnke [Email] (more from K.Daehnke) on Sat, 30 Jul 2011 07:51:11 Share Post by Email
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It's no go for passing the bi-annual emissions test here in Northern VA due to the ironic fuel vapor leak of my 1999 9-5. The irony is the leakage being at the base of the plastic pedestal where the leak sensor sits!! This should have been a Saab recall item many years ago. Anyway, I bought the aircraft epoxy others have recommended, but I'm going to drop the tank anyway to get at an underbody rusted area as well. What I'm going to try differently is heat welding the defective seam where the pedestal meets the tank. I came upon a company that sells separate repair kits for plastic kayaks and ATV fender repair. The tech I talked to recommends the ATV fender repair kit as the welding tool (like a soldering iron) tip is smaller and might be best for the 90 degree seam I'm trying to repair between the pedestal and the tank body. I'll be buying the stainless steel reinforcing screen and the appropriate polyethelene filler rods to melt on. Seems more natural to employ this than the aircraft epoxy method. I have the WIS shop manual which has an entire section devoted to heat welding the various plastics and plastic items throughout the car body, but not the fuel tank. I once before successfully welded back together the cracked squirrel cage fan of my heater blower with just a soldering iron, so I know this technique should work. I'll post more of my success or failure.

Kirk D

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