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  1. #1
    Trooper182's Avatar
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    Fixed my cracked fuel pump hose connector piece. Maybe will help you

    Ok so yesterday I was doing the fuel pressure regulator fix on both of my virage ski's. After removing the part with the 3 hose connectors I found that one of the ports where the fuel supply nipple connects in was cracked. Of course this part is hard to find and I'm not made of money and don't want to buy a whole new fuel pump. So I decided to attempt to fix this myself. This is my first time doing a repair write up so go easy on me lol. On to the repair

    This is the crack I'm talking about.
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    I thought about using "Seal All" as it is a fuel resistant epoxy but I don't know how well it would hold up. So I went to Harbor Freight and bought a plastic repair iron kit. The kit was $16.00 US. I also got a set of precision mini files for $3.00. Click image for larger version. 

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    First thing I did was glue the fitting in place using the Seal all. Once that set in I heated up the iron. Obviously be very careful using the iron. It heats to over 500 degrees Fahrenheit.

    Starting at the base of the crack use the tip of the iron to heat the plastic and slowly drag the heated material into the crack. Do this from both sides of the crack. Make sure you do not just hold the iron on the plastic or it will melt through very fast. Take your time and work slow. I also used the filler plastic rods to add material in. Set the filler rod on top of the crack and use the iron to melt the rod and drag the material on top of the crack. When you are done it should look like this.
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    Next use the flat side of the iron to smooth out the plastic as much as you can.
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    Next I used the files to finish flattening out the plastic. Once that is done the crack is effectively sealed and bonded.
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    Now the iron kit also comes with some steel mesh to help add strength. I decided to use this also. I cut a thin strip and molded it around the piece to get the shape. Then using the iron, I melted one end of the mesh into the plastic and let it cool. I then used the iron to work the metal into the plastic. The iron tip is shaped like a triangle. I found the easiest way to work the metal in is to use the side of the iron tip and in a see-saw motion, work the metal into the plastic.
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  2. #2
    Trooper182's Avatar
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    I did this process to both sides. When I was using the tap to tap the hole for the new barbed fitting I accidentally went in kind of at and angle. As a result, the threads got very close to the outer wall. So to be on the safe side I added wire mesh and filler to that side also.
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    I pressure tested everything with 30psi of air and no leaks. Everything is back installed and should work fine. This is a very strong repair as you are using the original plastic and filler to rebond the material vs. using something like epoxy to hold it all together. Plus the metal mesh adds extra strength.

    Word of caution. The fumes produced are toxic and will irritate your eyes and are not good to breath in. I had a fan off to the side so it would blow the fumes away and had my garage open. I hope this will help someone out as this repair can be used for many other things. Figured I would try and contribute something to this forum as it has already helped me immensely in the last few weeks.

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  4. #3
    Trooper182's Avatar
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    So upon further inspection of the fuel pump, it looks like the crack was caused a while back. I found what looks like some sort of sealant inside of the fuel pump body. Looks like it probably wasn't fuel safe ad degraded over time. All the more reason I went with the plastic weld.Click image for larger version. 

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  5. #4
    Trooper182's Avatar
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    Finished product.Click image for larger version. 

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  6. #5
    Click avatar for tech links/info K447's Avatar
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    Quote Originally Posted by Trooper182 View Post
    Not sure how, but you might want to confirm the patched ‘plug’ is still air tight in the rubber grommet. Fuel fumes inside the hull are not a good thing, and potentially explosive.

  7. #6
    Trooper182's Avatar
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    Good point and I was thinking the same thing. I have a Combustible Gas Leak Detector and I'm going to test the air in the hull. I'm leaving everything sealed up over night and will test the air quality tomorrow. But so far everything is firmly in place.

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