I will try to keep this "ible" short and sweet.
Note I also took apart and cleaned and re-lubed all of the O-rings, and the venturi. If you are going to have it taken apart you should just complete the tuneup as well, so I did. That's not part of this instructable. Sorry.
Here are some good links
Step 1: Materials and Tools List
Permanent marker (I use Sharpies)
Small piece of cardboard
Step 2: Disassemble the Unit
Using your permanent marker, if you know where the leak is, make a reference mark for later. In this case I do know where it is because salt is coming out of the crack.
Disassemble the water softener and remove the insides so you only have the reservoir.
Empty the salt in a safe location "INFO NOTE" salt will kill your plants don't pour it, or any left over salt brine water, in your yard.
Spray out inside of reservoir until it looks clean. Then dry out with a towel or let it air dry, your choice.
Step 3: The Repair
Since I am to big to crawl into this thing I will have to repair this thing from the outside in.
2. Grab your sandpaper, use your sand paper to rough up the area where the crack is. Rough the area up to about 1 inch in diameter around the crack. after you have done this wipe the dust off of the area of the reservoir.
Step 4: Prep the Materails
Step 1. Mix your epoxy. Mix your epoxy on a portable surface something you can carry while you crawl in to the reservoir. I normally use a piece of cardboard and a Popsicle stick, this time I used a paper plate I also use 5 minute epoxy.
Step 2. Have a small bowl of water and some dish soap nearby. You can mix some soap in the water if you like.
Step 5: Application of Repair
Step 2. Using your Popsicle stick that you mixed your epoxy with, apply some of the recently mixed epoxy on the sanded area of the reservoir. You can be liberal with it.
Step 3. Try to make it neat looking (because you take pride in your work even though no one is going to see it).
Step 4. After you have put some epoxy on your repair area put some dish soap on your fingers, or use your soapy water and smooth out the epoxy. I take mine all the way to the tape edges. Use a little pressure to try to push the epoxy into the crack. It would have been better to apply it to the inside of the reservoir but since I could not fit or reach the bottom I was left repairing it this way.
Step 5. Ok Now that you have everything smoothed out with your fingers and slippery soap peal the tape off. Then once again use your soapy fingers to smooth the edges of the epoxy area. Now it should be looking good.
Step 6. After you have completed Step 3. let the epoxy cure in accordance to the package directions.
Step 6: Leak Check
Step 2. If you are good to go after step one reassemble all pieces of the water softener and add new salt.
Step 3. Initiate a manual recharge of your softener and let it run its cycle. Periodically checking to make sure that your repair is not leaking. If no leak then you are good to go. That's it.
Step 4. If you have another leak start the process over, work more diligently and make sure that you have done a proper job in all steps. If it just wont stop leaking you could get a new reservoir, sometimes manufactures warranty the reservoir for up to 10 years. It could be a hassle to do this part and i didn't really want to find out if it was a hassle or not.
Step 5. There is always duct tape. :)
Good luck with your project.