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

[George B]

Just looking for options. I would not be happy with the crappy design they used either. The fill tee looks simple enough too.

 

[iamdub]

I don’t know, I might try. It’s on an ear of the tank. It’s leaking on the inside of this hole. The problem is if I make it worse and it won’t hold coolant in the system I probably shouldn’t drive the truck.View attachment 247653

First I was thinking you could go at it with a tiny drill bit at a shallow angle to "route" out a slot along the leaking seam, then pack it with epoxy. Now I'm thinking you could use a thin cut-off disc to slice the seam on the whole ear, spread it apart with a screwdriver or wide pry tool, fill the entire ear full of epoxy and clamp it back closed to cure.

 

[Rocket Man]

Looking back I see that now. Must be flat head screws. Is that ear hollow?

Yes flat head Allen head screws and yes the ear must be hollow, there’s a seam that runs right through both mount holes horizontally instead of that part being solid plastic like you would think it would be. Like I said, it’s a shit design. That plastic seems to squish down when I tighten the screw down. Probably why the epoxy i flowed in from inside the tank didn’t fix it.

 

[George B]

Yes flat head Allen head screws and yes the ear must be hollow, there’s a seam that runs right through both mount holes horizontally instead of that part being solid plastic like you would think it would be. Like I said, it’s a shit design. That plastic seems to squish down when I tighten the screw down. Probably why the epoxy i flowed in from inside the tank didn’t fix it.

Thats ******!

 

[Rocket Man]

First I was thinking you could go at it with a tiny drill bit at a shallow angle to "route" out a slot along the leaking seam, then pack it with epoxy. Now I'm thinking you could use a thin cut-off disc to slice the seam on the whole ear, spread it apart with a screwdriver or wide pry tool, fill the entire ear full of epoxy and clamp it back closed to cure.

I actually thought about doing that but was thinking that might open up a can of worms but you might be right, now that someone else thought of it maybe it’s not so crazy after all. I might give it a try, hopefully I don’t mess up the tank worse than it is.

 

[iamdub]

I actually thought about doing that but was thinking that might open up a can of worms but you might be right, now that someone else thought of it maybe it’s not so crazy after all. I might give it a try, hopefully I don’t mess up the tank worse than it is.

After using that JB Weld Plastic Epoxy to repair a few mounting tabs for some rather large headlight assemblies, I'd trust it or anything similar. Having the whole ear filled to keep it from squashing should be a permanent fix. I'm thinking you'd fill one half and let it sit until the epoxy sets up enough to stay in place when inverted, then flip it to fill in the other half as quickly as possible, remove your spreader tool so the two filled halves connect, then lightly clamp and let cure.

 

[Sam Harris]

Thats ******!

X2

 

[pwtr02ss]

After using that JB Weld Plastic Epoxy to repair a few mounting tabs for some rather large headlight assemblies, I'd trust it or anything similar. Having the whole ear filled to keep it from squashing should be a permanent fix. I'm thinking you'd fill one half and let it sit until the epoxy sets up enough to stay in place when inverted, then flip it to fill in the other half as quickly as possible, remove your spreader tool so the two filled halves connect, then lightly clamp and let cure.

That JB plastic weld is awesome.

 

[randeez]

Yeah but are you trying to save me money or cost me money because those options are all over $125....some are waaaaaay over lol.

Let me know if you need anymore help spending money, I'm pretty good at it

 

[Rocket Man]

Let me know if you need anymore help spending money, I'm pretty good at it

Yeah, I thought I was bad until I started watching you. Now I feel better.

 

[randeez]

I clicked on the link George posted and wasted about a a half hour looking at overflow tanks for myself