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Plastic Repair. Level One Apprenticeship. What you need to know. Ability to identify the type of plastic Proper steps to achieve correct results Which method of repair? Will the repair be satisfactory? Is it cost effective? Do you have all the necessary materials?

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Plastic Repair


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    1. Plastic Repair LevelOne Apprenticeship

    2. What you need to know • Ability to identify the type of plastic • Proper steps to achieve correct results • Which method of repair? • Will the repair be satisfactory? • Is it cost effective? • Do you have all the necessary materials? • Are we allowed to repair the part? • Is it a Thermoset, or a Thermoplastic?

    3. Plastics Usage Through the Years 1970 1980 1990 2000+

    4. Where are these plastics used? • wheel housings and liners • exterior body panels • valve covers • composite plastic floor tunnels • virtually anywhere • fascias • bumper covers • interior trim • exterior trim • fan shrouds • batteries • gas tanks

    5. Viper... Is a perfect example of Plastics and performance

    6. Future Technology

    7. Methods of Identification • ISO Code • Body Repair Manual • Sanding Test • Float Test • Flexibility Test • Rod Adhesion Test

    8. ISO Code Identification

    9. Other means of Identification PET(E) PP HDPE PS PVC Other LDPE

    10. TheMitchell Manual is another source for plastic identification information

    11. What is TPO, ABS or PUR ?

    12. Plastic Locations

    13. Oldsmobile Aurora

    14. Saturn Station Wagon

    15. PE / Polyethylene

    16. PP/Polypropylene

    17. Saturn

    18. Hummer H2

    19. Thermoset vs. Thermoplastic

    20. Repairing Plastics

    21. Identifying the Extent of Damage • One sided Repair - Nick, Scratch or gouge • Two sided Repair - Puncture, Rip or Tear • Reshaping with Heat - Dents or distortion

    22. Damage Identification

    23. Repair Methods • Welding • Hot Air Welding • Airless Welding • Ultrasonic • Adhesive • Olefin • Non-Olefin • Rigid • Flexible

    24. Repair Method Recommendations

    25. Steps for Welding or AdhesiveRepair • Thoroughly wash part with soap and water • Warm soapy water • Aids in cleansing water soluble materials • Secondary damage becomes apparent • Wax and Grease remover • Cleans surface of waxes and silicones • Removes non-water soluble materials, such as road tar

    26. Once clean, use heat if necessary to reshape panel and remove any distortion • Heat gun • Heat lamp • Make repair decisions • One sided repair? • Two sided repair? • Which method of repair will be appropriate? • If cosmetic, Adhesive repair will suffice • If torn, a two sided repair will be needed • Will an Adhesive or a Welding repair be stronger?

    27. Safety First! - With the vast amounts of chemicals found in plastics and adhesives today, following the proper safety precautions should be first and foremost when performing any repair procedure

    28. Do Not Repair!

    29. Types of Adhesive Repairs

    30. Adhesive Repair • Tools needed for a one-sided repair • Sander (D/A or Single action) • Sanding block • Air nozzle • Materials • Plastic cleaner • Adhesion promoter (if polyolefin) • Repair material (2-part) • 120-180 grit sandpaper

    31. One Sided Repair

    32. One Sided Repair Procedure • Featheredge the nick, scratch or gouge to the base of the damage • Clean area by blowing away leftover dust • Clean sanded area with approved plastic cleaner (Do not mix systems) • Wash clean and dry • Apply adhesion promoter if necessary • Mix chosen repair material correctly and apply • Sand material to desired finish

    33. Two Sided Procedure • Tools • Die grinder • Small grinder (50 grit) • DA sander • Blow gun • Spreaders • Clamping devices • Materials • Backing materials • Repair Adhesive and adhesive promoters • Abrasives

    34. Two Sided Repair

    35. Two Sided Repair

    36. Repair Materials Do not intermix materials!

    37. Cleaners • Plastic cleaners are important for a couple of reasons • They aid in removing surface contaminants left from the manufacturing process • Help cleanse the surface of contaminants left from the sanding and grinding process

    38. Repair Adhesives • Procedures vary from manufacturer to manufacturer • Materials and their characteristics will vary as well • Can be made up of Epoxies, Urethanes or Acrylics • All have different curing times and sanding / handling times • Procedures are all brand and material specific

    39. Curing times Example only

    40. Applicators

    41. Using the Mixing Guns • Insert Cartridge into applicator gun • Remove protective cap from cartridge • Purge cartridge to equalize contents • Install new mixer tip • Gun out approximately 1 1/2 - 2 inches of mixed material to ensure proper mixing on waste material • Apply material to repair area, keeping the mixing tip in the applied adhesive

    42. Once all Material needed has been applied, leave used mixing tip in place on cartridge • Release pressure from cartridge and remove cartridge from applicator gun • Store leftover cartridge in a cool, dark environment • Shelf life of a used cartridge is usually one month, an unused one is a year

    43. Reinforcement Materials • Can consist of mesh materials • Loose Fiberglas mesh • Woven Fiberglas cloth • Can consist of materials consistent with the material being repaired • Leftover or discarded plastics of similar makeup

    44. Adhesion Promoters • Are used primarily for improving the adhesion characteristics of Olefin based plastics • Improve adhesion by chemically changing the surface of the Olefin plastic, allowing an adhesive to bond with it • Other methods include a flame treatment to promote adhesion

    45. Minor Repairs • Instant Adhesives, or ‘crazy glue’ have their place in the bodyshop as well as 2-part adhesives • Serve well for minor replacement of broken tabs or mounting hardware • Limited strength

    46. Plastic Welding Hot Air and Airless

    47. Plastic Welders

    48. Hot Air Welding

    49. Hot Air Welding Tips