Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

[George B]

I have some Lord Fusor plastic repair epoxy, it’s the best stuff I have found. I found out about it from the bike builders when I cut my Harley fairing and raked it so my headlight wasn’t pointed at the sky when I raked the bike for a 28” front wheel. It had to be the best to hold that plastic together with the way a Harley shakes and vibrates. It never cracked or showed any sign of weakness. My issue I think is finding the leak, it looks like it’s coming from one of the mounting holes and only leaks, barely a drip, when it heats up and the system is under pressure. Whipple said it’s pressurized at 5-8 psi. I’ll know more tomorrow when I pull it off. I forgot to go pick up my 05 hatch glass today so I’m gonna do that tomorrow before I pull the reservoir.

Lord Fusor Plastic Repair Adhesive, Fast, 10.1 Oz. Part #:Fus-142 https://www.amazon.com/dp/B00B3HY53C/ref=cm_sw_r_cp_tai_5r2UEbRT91Y98

Throw a little air pressure in it and soap it.

 

[Tonyrodz]

I have some Lord Fusor plastic repair epoxy, it’s the best stuff I have found. I found out about it from the bike builders when I cut my Harley fairing and raked it so my headlight wasn’t pointed at the sky when I raked the bike for a 28” front wheel. It had to be the best to hold that plastic together with the way a Harley shakes and vibrates. It never cracked or showed any sign of weakness. My issue I think is finding the leak, it looks like it’s coming from one of the mounting holes and only leaks, barely a drip, when it heats up and the system is under pressure. Whipple said it’s pressurized at 5-8 psi. I’ll know more tomorrow when I pull it off. I forgot to go pick up my 05 hatch glass today so I’m gonna do that tomorrow before I pull the reservoir.

Lord Fusor Plastic Repair Adhesive, Fast, 10.1 Oz. Part #:Fus-142 https://www.amazon.com/dp/B00B3HY53C/ref=cm_sw_r_cp_tai_5r2UEbRT91Y98

Since you didn't know the exact location of the leak, that's why I suggested the spray Flex seal. You could just spray the entire bottle a few times. A cover all.

 

[Rocket Man]

Since you didn't know the exact location of the leak, that's why I suggested the spray Flex seal. You could just spray the entire bottle a few times. A cover all.

No thanks, I’m not using some hokey stuff like that. I don’t mean to offend at all Tony, but I just can’t do that kind of repair. It reminds me of how my dad used to fix shit, and it was always a joke bless his soul. If I can’t fix it right I’ll just buy the kit from Whipple. The problem I think I’ll have with finding the leak is first, I have to seal the inlet and outlet holes somehow, then find a way to add air pressure but not too much. If it’s too much hassle I don’t mind spending money, I just won’t until I know it’s the best way to fix this. I almost just ordered the kit today but figured I would at least give it a go.

 

[Tonyrodz]

No thanks, I’m not using some hokey stuff like that. I don’t mean to offend at all Tony, but I just can’t do that kind of repair. It reminds me of how my dad used to fix shit, and it was always a joke bless his soul. If I can’t fix it right I’ll just buy the kit from Whipple. The problem I think I’ll have with finding the leak is first, I have to seal the inlet and outlet holes somehow, then find a way to add air pressure but not too much. If it’s too much hassle I don’t mind spending money, I just won’t until I know it’s the best way to fix this. I almost just ordered the kit today but figured I would at least give it a go.

Oh man Mark, not offended at all. We all know that you like doings things the right way. I was just throwing an idea out there.

 

[Doubeleive]

ya you could fill it with air and put it in a tub of water, like checking for a leak in a tire, I would try to repair it from the inside, maybe once you locate the precise spot, rotate the tank so that the crack is the very bottom and pour some epoxy inside so it fills in that particular spot, effectively sealing it. just an idea

 

[05Single]

Lol funny I just used this on a recent project and put flex seal tape over it

but that’s cause nobody sells what I’m making

 

[Rocket Man]

Lol funny I just used this on a recent project and put flex seal tape over it View attachment 247025
View attachment 247026
but that’s cause nobody sells what I’m making

Why did you add Flex Tape? Fusor doesn’t need that. I used their 142 Plastic Repair on my custom cluster bezel for structural and their 114LG Finishing for feathering. And I have bent and twisted that with no cracking or separation. The stuff is awesome.

 

[pwtr02ss]

I was going to suggest plastic weld, but you're on it. I'd say that once you get out out of the vehicle, you'll be able to spot the leak.

 

[Rocket Man]

Got the hatch glass. Returned the hatch glass. Ordered another hatch glass. I don’t know how LKQ makes any money.

 

[Tonyrodz]

Got the hatch glass. Returned the hatch glass. Ordered another hatch glass. I don’t know how LKQ makes any money.

View attachment 247115 View attachment 247116 View attachment 247117

Hard to tell from the pics--Was it scratched up?