Octane Octane water box issues

[jplutinof]

Waterbox broken again. I broke the original water box on my 2003 octane. I gusseted it and then broke something internal so I replaced with TDR 3 yrs later the seam split at the weld. Should I fix the weld or buy a new (expensive as hell) oem box and have it gusseted as well? It's such a pain to get in and out cause of the fuel tank. Any help would be greatly appreciated.

 

[jplutinof]

Waterbox broken again. I broke the original water box on my 2003 octane. I gusseted it and then broke something internal so I replaced with TDR 3 yrs later the seam split at the weld. Should I fix the weld or buy a new (expensive as hell) oem box and have it gusseted as well? It's such a pain to get in and out cause of the fuel tank. Any help would be greatly appreciated.

So I gusseted a new OEM box and welded the seam shut on the TDR box. Here's a few picks.

 

[jplutinof]

So I gusseted a new OEM box and welded the seam shut on the TDR box. Here's a few picks.

Installed the OEM box

 

[jplutinof]

Might need more or better padding under and around the Waterbox to absorb shock and vibration...

I added more padding at top to make it more securely held in place. All pipes line up perfectly so I've removed that factor. I also for years had my fire extinguisher tied to the exit pipe next to battery which I've now removed. No more fire extinguisher .lol

 

[TheBuzzard]

Octane waterbox with the extended nipples were prone to breaking off. It just happens. S r 800 does the same. Fix it or just put a stock round nose box in there and use longer hoses.

 

[jplutinof]

Octane waterbox with the extended nipples were prone to breaking off. It just happens. S r 800 does the same. Fix it or just put a stock round nose box in there and use longer hoses.

Well hopefully I've fixed it. The fuel tank is a pain to get out. Though I've gotten pretty good at it. Lol

 

[TheBuzzard]

You have to put the battery and box on sj and octane to get the tank out

 

[jplutinof]

You have to put the battery and box on sj and octane to get the tank out

I pulled the fly wheel screw on top out and pipe extension on the right, as well as battery and bat holder then it pops out with a little effort.