Omar Khalid
Plastic car parts can become brittle and prone to breaking over time. Luckily, there are several ways to repair them, ranging from simple glue-based fixes to more complex welding techniques. Before repairing, it is important to identify the type of plastic and the extent of the damage, as this will determine the best method to use. Repairs can be categorised as either cosmetic, addressing surface issues, or two-sided, which are needed for more severe damage like tears or holes.
| Characteristics | Values |
|---|---|
| Repair methods | Cosmetic repairs, two-sided repairs, grinding, heating, plastic welding, using repair adhesives, using epoxy filler material, using ABS cement, using cyanoacrylate glue, using a heat gun, using a grain pad, using Vaseline |
| Plastic types | Polymer blends, reinforced plastics, nonreinforced plastics, TPO plastics (Thermo Plastic Olefin) |
| Tools | Plastic solvent, plastic welder, filler rod, universal plastic filler rod, adhesion promoting spray, mesh tape, JB Weld, cyanoacrylate glue, sandpaper, Scotch-Brite pad, drill, screw, razor blade, glue accelerator, texture mold, silicone, syran wrap |
| Plastic properties | Plastic tends to be oily, plastic becomes brittle and cracks with age, some plastics ooze chemicals that repel paint and adhesives |
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What You'll Learn
Identify the type of plastic
There are several types of plastics used in the automotive industry, and it can be challenging to differentiate between them when repairing a vehicle. The type of plastic used in a car part is usually identified through a number plate or identification code located inside the part, which specifies the exact composition of the part. This code will help you determine whether the part is a thermoplastic or a thermoset material, and whether it is rigid or flexible.
Float Test
If there is no SAE code, you can perform the float test. Cut a shaving of plastic from the back of the part. Make sure the shaving is free of mold release agents and paint. Place the shaving in a container of water. Thermoplastic polyolefin will float, while thermoset non-polyolefin will sink.
Grind Test
Another method is to lightly grind the plastic to see if it smears or powders. If it smears, it is a thermoplastic. If it powders, it is a thermoset.
Sand Test
Using a Grade 36 Roloc™ Disc, sand a spot near the damaged area. Thermoplastic polyolefin will melt or fray, while thermoset non-polyolefin will sand cleanly.
Burn Test
The burn test has been used for years to rule out certain plastics, but it is difficult to specifically identify a plastic.
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Cosmetic vs two-sided repairs
When it comes to repairing plastic car parts, there are two main categories of damage: cosmetic and two-sided repairs. Understanding the differences between these repair types is crucial for car owners and technicians alike, as it informs repair decisions, costs, and safety considerations.
Cosmetic repairs address surface-level issues that affect the appearance of a vehicle. This includes scratches, minor dents, chipped paint, and other similar flaws that don't hinder the vehicle's functionality. These types of repairs are typically faster and more cost-effective, ranging from $150 to $1,500. Many cosmetic issues can be addressed through DIY methods or simple techniques like paintless dent repair (PDR) and touch-up paint.
On the other hand, two-sided repairs are necessary when there is more severe damage that goes completely through the surface of the plastic part. This includes tears, holes, or cracks. Two-sided repairs require more extensive techniques such as plastic welding or the use of repair adhesives. The repair process for two-sided damage also differs between reinforced and non-reinforced plastics, with methods like grinding and heating being utilized to address the damage effectively.
It is important to note that before initiating any repair work, technicians must identify the type of plastic or polymer used in the car part. This identification guides the selection of appropriate repair methods and ensures the best chance of success. Additionally, most plastic repairs involve a refinishing process after the initial repair to match the repaired part seamlessly with the rest of the vehicle.
Plastic repair products and techniques have become increasingly important in collision repair shops, as they reduce the time and cost associated with fixing damaged parts. By using these products, technicians can make repairs without having to wait for new parts to be ordered, providing a more efficient and cost-effective solution for customers.
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Use of adhesives
When repairing plastic car parts, adhesives are a crucial tool. The use of adhesives, or glue, is a common method for fixing cracks, tears, and holes in plastic car parts. It is important to identify the type of plastic being repaired, as different plastics require specific adhesives and repair techniques. For example, polypropylene (PP) and acrylonitrile butadiene styrene (ABS) are common types of plastic used in car parts, as identified by the International Standards Organization (ISO) guidelines.
The first step in using adhesives to repair plastic car parts is surface preparation. This includes thoroughly cleaning the area to be repaired with a suitable cleaner, such as an all-purpose cleaner or acetone, to remove any dirt, grease, or residue. Roughening the surface with sandpaper can also help create a better bond for the adhesive. Additionally, identifying the type of plastic and determining the correct adhesive is crucial. Different adhesives have specific mixing ratios and curing requirements, so it is important to follow the manufacturer's instructions.
Once the surface is prepared, the adhesive can be applied. It is important to use the correct amount of adhesive and spread it evenly over the repair area. If filling cracks or gaps, it may be necessary to use a thicker adhesive, while thinner adhesives are better suited for bonding parts together. In some cases, an accelerator may be needed to cure the adhesive quickly, such as with cyanoacrylate glue.
After applying the adhesive, clamping or holding the parts together may be necessary to ensure proper bonding. It is important to follow the recommended curing time for the adhesive before handling the repaired part. Once cured, the excess adhesive can be removed with sandpaper, and the repaired area can be refinished with paint or another coating to match the surrounding plastic.
Using adhesives to repair plastic car parts requires careful preparation, the right tools, and safety precautions. It is important to wear appropriate safety gear and work in a well-ventilated area when using adhesives and other chemicals. By following these steps and choosing the correct adhesive, most plastic car parts can be successfully repaired.
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Plastic welding
To begin the plastic welding repair process, technicians first identify the type of plastic and whether it is fibre-reinforced. This identification is crucial for selecting the appropriate repair methods and ensuring the success of the repair. Common types of polymers used in car parts include PP (polypropylene) and ABS (acrylonitrile butadiene styrene).
The next step is to clean the repair area with a plastic solvent and hold the plastic welder to the edges of the crack. It is important to start with a low-wattage soldering iron, as a higher temperature can vaporize the plastic and cause more damage. The iron should be turned so that the flat side is facing up, and then gently pressed into the plastic. The goal is to melt about 50% through the plastic, starting before the end of the crack and continuing past both ends to seal the crack and prevent it from spreading.
Once the plastic is melted, a filler rod can be added and melted into the crack. This filler rod can be purchased in various types of plastic to match the specific type of plastic being repaired. Alternatively, a piece of the bumper being repaired can be used as the filler material, ensuring compatibility. The excess filler material is then spread around with the flat part of the welder, creating a strong "stack of pennies" look.
After the plastic has cooled, the repaired area may still have visible cracks on the other side. To address this, the part can be flipped over, and the joint can be gently melted again with the flat side of the iron to smooth out the surface.
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Drilling and sanding
When repairing a crack in a plastic car part, drilling a series of holes on either side of the crack can add another place for the filler to grab onto. This technique is similar to the use of rebar in cement. After drilling, the repair area should be thoroughly cleaned and sprayed with an adhesion promoter to ensure the filler adheres properly.
Sanding is an effective method for rejuvenating plastic car parts and restoring them to their former glory. It is important to start with a test area to determine the appropriate grit and prevent potential damage. Sanding should be done in a circular or back-and-forth motion, applying even and gentle pressure to avoid creating low spots or uneven surfaces.
The sanding process typically begins with coarse-grit sandpaper, such as 400 or 800, and progresses to finer-grit sandpaper, such as 1000 or 1500. The surface should be regularly wet with water or lubricant to prevent the sandpaper from clogging and to reduce heat buildup, which can deform the plastic.
After sanding, it is important to wipe away any residue, dry the surface, and apply a dedicated plastic polish to achieve a glossy, like-new finish. With the right knowledge and techniques, sanding can bring a fresh look to a vehicle, making it appear revitalized and well-maintained.
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