I recently had a failure on the coolant tank on my 2002 3.0 X-Type. I searched the forums and all of the posted repairs were for the upper nipples. Unfortunately mine was the lower nipple for the main hose.
I just completed repairs and in case anyone else needs it the repair is working.
1. I first cut off the broken nipple flush with the boss and then used a block and sand paper to make it flat.
2. I cut a short section of 1/2 inch CPVC piping and using CPVC glue attached it to a 1/2 inch coupling.
3. I the cut off and sanded square the section of the original nipple with the boss.
4. Once the boss was prepped I added a length of CPVC to the other side of the coupling and placed the boss on it and cut it to the proper length.
5. I used JB Weld Epoxy to assemble everything. I made sure to follow the instructions of roughing up the surfaces using sandpaper on a rod for the interior and the cleaning everything with Brake Cleaner before applying the epoxy.
6. I let everything dry overnight and successfully reinstalled and no LEAKS.
I will re-post in a couple of weeks and let you know about the durability. I had to come up with a repair because it is a daily driver a used tank is a week away.
Pictures are attached.

 

Great job..But I would have bought a new tank and been done with it....they are made better than the originals...Hope your's holds up..

 

I know you have a sense of accomplishment, but they are so cheap to replace. I have one as a spare just in case! If I were you, I would go ahead and get one and plop it on the shelf for later!

Expansion Tank

 

New one is ordered but a week out from arriving.

 

aaah!...I See the method to your madness...I would've done the same thing to keep it rolling, til the new one arrived..Nice work

 

It broke Saturday evening and have to drive 230 miles to a job site on Monday. Necessity is the Mother of innovation. If anyone else gets stuck it does work 510 miles on the repair, no leaks all is good, but anxiously awaiting for the new tank to arrive.