coolant bottle repair

Message

wistech · #1 Post by **wistech** » Fri Jan 21, 2011 4:54 pm

Here is how to quickly and permanently repair the dreaded coolant nipple. They usually break off during engine repairs or during a rollover. First take a flange head bolt a little over an inch long and drill a hole through the center. This is an 8 X 1.25mm. An 1/8" drill or whatever you have works.

wistech · #2 Post by **wistech** » Fri Jan 21, 2011 4:56 pm

Now grind down the flange with a grinder of cutoff wheel so it has a trianglular top. This is for clearance in the corner of the tank .

wistech · #3 Post by **wistech** » Fri Jan 21, 2011 5:00 pm

Now grind flat and roughen up the surface where the nipple has broken off. Dont go to far. Then drill out the hole big enough for the bolt to fit in. Coat the bolt with your favorite epoxy . I prefer clear 2 stage plastic epoxy but here we will be using JB weld. Then drop the bolt in the bottle and you can use one finger and gravity to get it through the hole you just drilled from the inside.

wistech · #4 Post by **wistech** » Fri Jan 21, 2011 5:08 pm

Now install a flange head nut on the bolt and snug it down . Do not overtighten as its plastic you dealing with and if cranked down to hard it will pull the bolt through the plastic.
I like to leave a little epoxy on the threads dont bite to hard into it for easier removal. Let is sit till the epoxy has cured and say goodby to an annoying problem and can be done quickly and costs next to nothing.

jesshamner · #5 Post by **jesshamner** » Fri Jan 21, 2011 6:29 pm

You break that little thing off in a rollover? Good god man! Sounds a little more severe than a rollover.

wistech · #6 Post by **wistech** » Fri Jan 21, 2011 7:39 pm

Actually its right next to the plastic and can snap off with a little weight applied to it in a roll over or just landing hard while mxing. Especially if you lose a hold down bolt or cut the fenders. I broke one just rolling the quad in deep snow . No damge to anything but the snow shoved the plastic into the bottle and cracked the fitting. The vast majority are broken from engine removal.

jesshamner · #7 Post by **jesshamner** » Fri Jan 21, 2011 9:41 pm

LOL...Sounds like you need to keep it round side down.