Omar Khalid
Welding plastic auto body panels is a process that requires careful preparation and the right equipment. It is important to ensure that the welding current is set correctly to avoid creating holes in the panel or reducing the depth of the weld. Before beginning, it is crucial to have all the necessary MIG welding equipment, including a MIG welder, welding wire, gas, clamps, and a hand grinder. The replacement panel should be sized correctly and fitted to the existing frame to ensure no overlap. Removing rust from the car is essential to prevent it from spreading to the new panel. When welding plastic, it is important to work in a well-ventilated area or outdoors due to the release of toxic gases, and to wear protective gear to safeguard against burns.
| Characteristics | Values |
|---|---|
| Welding equipment | MIG welder, soldering iron, welding wire, gas, clamps, hand grinder |
| Welding wire | ER70-6 or ER70-7 |
| Shielding gas | 75-25 blend of argon and CO2 |
| Welding current | 40-60 amps |
| Plastic welding repair | Remove the damaged panel, cut the excess from the new panel, use clamps to hold it in place, weld, and stitch or bond any remaining gaps |
| Safety precautions | Work outside or with extraction, wear a mask to avoid inhaling toxic gases, be careful of burns |
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What You'll Learn
- Use a soldering iron with a large tip to weld plastic
- Melting plastic releases toxic gases—work outside and wear a mask
- Use a MIG welder for repairs, with a 75-25 blend of argon and CO2
- Measure panel thickness and ensure you have enough welding wire and gas
- Remove the old panel, then attach the new, correctly-sized panel
Use a soldering iron with a large tip to weld plastic
Welding plastic auto body panels can be done using a soldering iron with a large tip. This method can be used to repair car bumpers, dashboards, and other plastic parts. It is important to note that melting plastic releases toxic gases, so it is recommended to work outside or with extraction and wear a mask. Additionally, the plastic will get hot, so there is a risk of burns.
To weld plastic with a soldering iron, start with a low-wattage iron, around 25 to 30W, as hotter irons can vaporize the plastic and cause more damage. Turn the iron so that the flat side is facing up and gently press it into the plastic. You want to melt about halfway through the plastic. Start before the crack and continue past both ends to seal the crack and prevent it from spreading. Keep the iron moving and push the newly melted plastic towards the last melt, creating a strong weld.
It is important to maintain consistent pressure when welding to ensure a strong bond. Reinforcement can be added by using hot staples along the weld. Allow the welded area to cool naturally, as force-cooling can weaken the weld. Different types of welding techniques, such as butt welding, fillet welding, and spot welding, can be used depending on the specific repair requirements.
When choosing a soldering iron, look for one with adjustable temperature settings and a large tip to apply heat to a wider area. The Iroda Pro-25L, for example, offers fingertip control to prevent overheating and ensure the melting temperature is efficient for welding. Additionally, consider using a heat gun to preheat the weld area and keep the plastic flowing for longer.
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Melting plastic releases toxic gases—work outside and wear a mask
When welding plastic auto body panels, it is important to remember that melting plastic releases toxic gases, so it is essential to work outdoors or in a well-ventilated area and always wear a mask. The safest plastic to melt is PP and PE, as they are low in cyclic compounds and are essentially refined wax. However, even these plastics can release harmful toxins when burned, which can be extremely dangerous to your health and the environment. These toxins can include very harmful volatile organic compounds (VOCs) such as toluene, xylene, styrene, benzene, and ethylbenzene, which have been linked to an increased risk of cancer, respiratory illnesses, birth defects, and damage to internal organs and the hormonal system.
In addition to wearing a mask, it is recommended to use a portable fume extractor with a HEPA filter and activated carbon filtration to capture plastic fumes at their source before they can be inhaled. These filters adsorb chemical fumes, while the HEPA filter captures small particles. An alternative filtration method is to use a Local Exhaust Ventilation (LEV) system, which is an industry standard for ventilating toxic air efficiently. The LEV system consists of a hood, ducting, and a centrifugal fan to remove contaminants from the air.
Another important consideration is the type of plastic being welded. Some plastics, like acrylic, release generally harmless gases, while others, such as PVC, can release highly toxic compounds like dioxins when burned. It is crucial to identify the type of plastic before beginning the welding process and to take the necessary precautions to avoid inhaling any toxic fumes.
Furthermore, it is important to use the correct tools and techniques when welding plastic auto body panels. A soldering iron with a large tip is typically used for the weld, but it is important to start with a low wattage to avoid vaporizing the plastic and causing more damage. The iron should be turned so that the flat side is pointing up, and gently pressed into the plastic to melt about 50% of the way through, sealing the ends of any cracks and stopping them from spreading.
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Use a MIG welder for repairs, with a 75-25 blend of argon and CO2
When repairing plastic auto body panels, it is recommended to use a MIG welder, which is standard for repairs. The wire used should be ER70-6 or ER70-7, which can be easily found at a weld store. It is important to measure the panel thickness and follow the guide inside the welder for the best results.
For shielding gas, a blend of 75% argon and 25% CO2 is often used. However, some sources suggest that 100% argon gas is required for good results, especially when welding aluminum. It is worth noting that the presence of CO2 in the mix may not be suitable for welding aluminum due to its highly reactive nature, which can result in a bad weld.
When using a MIG welder, it is essential to control the heat to avoid blowout. This can be done by increasing the feed speed before turning down the heat. Additionally, overlapping welds by about 1/3 can help reduce the risk of missed spots or pinholes.
It is recommended to practice welding techniques on scrap metal before attempting to weld the actual auto body panel. Safety precautions, such as covering open interior or exterior glass with welding blankets and keeping a fire extinguisher nearby, should always be followed.
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Measure panel thickness and ensure you have enough welding wire and gas
When welding plastic auto body panels, it is important to measure the thickness of the panel to ensure a successful repair. The thickness of the plastic panels can vary, and this will impact the welding process and the required materials.
For plastic auto body panels, the thickness can range from 0.70 millimetres to 1.2 millimetres. It is important to note that if the plastic is too thin, the heat from the welding process might damage it, and if it is too thick, it will be difficult to bend and form the desired shape. Therefore, measuring the thickness accurately is crucial.
To ensure you have enough welding wire and gas, first determine the thickness of the panel and then refer to the manufacturer's recommendations for the specific type of welding wire and gas you are using. Different types of welding wires and gases will have varying feed rates and consumption levels. It is always a good idea to have extra welding wire available, as it is crucial to have enough to complete the weld without interruptions.
Additionally, when welding plastic, it is important to use a slower wire feed to allow the weld pool to penetrate fully and create a strong joint. This will also help you avoid overheating the plastic, which can release toxic gases. Always work in a well-ventilated area or outdoors, and wear a mask to protect yourself from any harmful fumes.
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Remove the old panel, then attach the new, correctly-sized panel
To begin the process of removing the old auto body panel, you will need to gather the appropriate tools. The specific tools required may vary depending on the vehicle and the type of panel being removed. For instance, if you are removing a door panel, you will need a screwdriver and a pair of pliers. You may also need a clip removal tool kit, which is available at a reasonable price. If you are removing a dashboard panel, you will need to disconnect the negative battery cable to avoid causing electrical damage.
Once you have the necessary tools, follow these steps to remove the old auto body panel:
- Remove any screws or fasteners holding the panel in place. Set the screws aside in a safe place so they do not get lost.
- Use a pair of pliers to gently remove any clips or latches holding the panel in place. Be careful not to use too much force, as you may damage the clips or the vehicle.
- With the screws, clips, and latches removed, the panel should now be free. Carefully pull the panel away from the vehicle.
When the old panel has been removed, you can prepare to attach the new, correctly-sized panel. Measure the area where the new panel will be attached to ensure that the new panel is the correct size and shape. Clean the area to remove any dirt, grease, or debris that could interfere with the adhesion of the new panel.
To attach the new panel, you can use traditional methods such as riveting or welding, which typically require the skilled hands of an experienced panel beater. Alternatively, you can use chemically engineered super glues or cyanoacrylates, which bond on a molecular level and can reduce labour time by up to 50%. One example of such an adhesive is Power Grab N Bond, which can bond a wide range of materials, including plastics, with extreme strength and flexibility. With the development of these super glues, the attachment process has become faster and more efficient.
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Frequently asked questions
Melting plastic releases toxic gases, which can include cyanide, so it is important to work outside or with extraction and to wear a mask. The plastic and soldering iron will get hot, so be careful of burns.
You will need a soldering iron with a large tip, clamps, a hand grinder, and welding wire. If you are using a MIG welder, you will also need gas. Make sure you have enough of everything before you start.
First, remove the damaged panel from the car, taking care to properly remove the rusted area. Then, fit the new panel to the existing frame to ensure it is the correct size. If the new panel is too large, cut the excess using the hand grinder. Finally, weld the new panel in place, melting about 50% of the way through and sealing the ends of the crack.
