Omar Khalid
Welding plastic on an ATV is a cost-effective way to repair cracked or broken fenders. There are several methods to weld plastic, including using a plastic welder, fuse welding, or a soldering iron. Some people opt for a plastic renew kit, or to fill and reinforce the area with small pieces of plastic cut from hidden spots. It is important to note that the plastic may not be as strong as it was before welding, and the repair may be visible.
| Characteristics | Values |
|---|---|
| Repairing cracked ATV plastic | Possible with a plastic welder |
| Plastic welder cost | $20 on Amazon |
| Other repair methods | JB weld, super glue and baking soda, fiberglass mesh tape, duct tape, soldering iron, epoxy, hot glue |
| Plastic welder types | ATV Fender Welder, zig-zag metal stitches, fuse welding |
| Plastic welder benefits | Stronger than glue, repairs fully functional, cheaper than replacement |
| Plastic welder drawbacks | Visible repair, fumes |
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What You'll Learn
Using a plastic welder
Before you begin welding, ensure you select the type of plastic and colour that matches your ATV parts. The available plastic types include PP (polypropylene), LDPE (low-density polyethylene), and HDPE (high-density polyethylene). LDPE rods are generally recommended for repairing cracks or holes in ATV plastics. However, if you require better wear characteristics, HDPE rods can be used, but they result in slower and more difficult welds.
To start the repair process, clean the damaged area with a plastic cleaner. This ensures that the welding process is effective and safe. Once the area is cleaned, use the hot tip of your welder to tack the tear or crack. This will help secure the plastic before you begin welding. Next, apply aluminium tape to the front side of the damage to prevent the plastic from melting through the cracks.
Now, you can begin welding. Cut a piece of stainless steel reinforcing mesh to fit the crack. The mesh will strengthen the repair, similar to how rebar reinforces concrete. Bury this mesh into the plastic by pushing it down with the tip of the welder. It is recommended to do this on the backside of the plastic, as it may not look aesthetically pleasing. Allow the mesh to cool before proceeding.
Finally, feed the welding rod through the tip of the welder and begin to weld the crack. Work slowly and in sections to ensure the plastic melts completely through. Remember to do it in a well-ventilated area, as the fumes can be harmful. Once the weld is complete, you can smooth it out with the tip of the welder to enhance the appearance of the repair.
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Filler rod types
Filler rods are used in welding to join two pieces of metal or plastic together. When it comes to welding the plastic on an ATV, there are several types of filler rods that can be used, depending on the type of plastic being welded. Here are some common types of filler rods used for welding plastic ATV parts:
Polypropylene (PP) Filler Rods: Polypropylene is a common type of plastic used in ATV fenders and other parts. It is strong, durable, and has good impact resistance. Polypropylene filler rods are compatible with this type of plastic and can create strong welds.
Low-Density Polyethylene (LDPE) Filler Rods: LDPE is another type of plastic that is often used in ATV parts. It is flexible, lightweight, and has good impact strength. LDPE filler rods are suitable for welding LDPE plastic and can create flexible and impact-resistant joints.
High-Density Polyethylene (HDPE) Filler Rods: HDPE is a denser and more rigid form of polyethylene plastic. It is known for its high tensile strength and resistance to chemicals. HDPE filler rods are ideal for welding HDPE plastic parts on ATVs, resulting in strong and durable joints.
Acrylonitrile Butadiene Styrene (ABS) Filler Rods: ABS is a type of thermoplastic polymer that is strong, rigid, and impact-resistant. It is sometimes used in ATV parts, and ABS filler rods can be used to effectively weld and repair these components.
Polyvinyl Chloride (PVC) Filler Rods: PVC is a versatile plastic that is used in a variety of applications, including some ATV parts. PVC filler rods are designed to weld PVC plastic, ensuring strong and chemically resistant joints.
When choosing a filler rod, it is important to select one that is compatible with the type of plastic being welded. Using a filler rod made from the same type of plastic as the base material ensures a strong and durable weld. Additionally, it is crucial to follow the recommended welding techniques and safety precautions to achieve the best results.
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Soldering iron
Welding plastic on an ATV with a soldering iron is a valuable skill that can save time and money. Here is a step-by-step guide on how to do it:
Preparation
Firstly, ensure your work area is well-ventilated as welding plastic creates harmful fumes. Wear protective gear, including gloves, long-sleeved clothing, a dust mask, and polycarbonate glasses. Set up a heat-resistant work area and have a fire-resistant holster nearby to safely store the soldering iron when not in use. Ensure your work area is clean and free of any contaminants.
Preheating
Before beginning, preheat the plastic with a heat gun to prevent the weld from cooling too quickly. This will allow the plastic to remain pliable for longer, making it easier to work with.
Use a soldering iron with adjustable temperature settings. Start at a lower temperature to avoid burning the plastic. Gradually increase the temperature as needed, moving the iron quickly to avoid burning.
Welding
Clean the plastic surfaces to be joined and sand down any jagged edges. Warm up the soldering iron and run it along the seam, melting the plastic until it is soft and pliable. Adjust the pieces so they fit together correctly. Use smooth strokes with the soldering iron to completely weld the pieces together.
Reinforcement
For added strength, use hot staples along the weld. Insert them along the length of the weld to reinforce the joint and improve durability.
Cooling
Allow the welded area to cool naturally. Do not force-cool the plastic as this can cause stress and weaken the weld.
Finishing
Once the weld has cooled, finish the repair by smoothing out the weld. This will create a strong and seamless joint that is more durable and cheaper than replacing the plastic.
By following these steps, you can effectively weld plastic on your ATV using a soldering iron, ensuring a strong and durable repair.
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Drilling holes and sewing
To begin the process, you will need to drill holes at the ends of the cracks to prevent them from spreading further. It is important to carefully select the appropriate drill bit for the job. While some sources recommend the use of a spade bit, others suggest a sharp wood bit or flat boring wood bit for creating round holes. Additionally, a step bit can be useful as it starts off small and gradually increases in size as you drill. If you want a clean hole, a hole saw attached to a regular drill with a small centre drill bit can guide you to the right spot.
After drilling the holes, you can "'sew up" the cracks using picture frame wire, zip ties, or other similar materials. This will result in a stitched-up appearance, similar to Frankenstein's monster, as described by some ATV enthusiasts.
The sewing process involves passing the wire or zip ties through the drilled holes on both sides of the crack and securing them in a manner similar to stitching. This technique ensures that the cracked plastic pieces are held together, preventing further cracking and providing a unique look to your ATV.
The drilling and sewing method is a creative and functional approach to repairing cracked plastic on ATVs, offering both stability and a distinct aesthetic to your vehicle.
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Painting ATV plastic
Preparation:
Firstly, it is important to choose an appropriate workspace that is well-ventilated to avoid inhaling any harmful fumes. Ensure your ATV is clean and free from any dirt, rust, or debris that may interfere with the painting process. It is recommended to use a plastic cleaner to ensure the surface is free of any chemicals or substances that might affect the paint adhesion.
Sanding:
Sanding is a crucial step in preparing the surface for painting. Start by sanding the entire surface with 180-grit sandpaper to remove any thin "crust" that may have formed due to exposure to the elements. For larger areas, you can use a sandblaster or 60-100 grit sandpaper, and for smaller areas, switch to 220-grit sandpaper. After sanding, scrub the plastic with a scuff pad to remove any remaining contaminants. Repeat the sanding process with 180-grit sandpaper to ensure a smooth surface.
Priming:
Before priming, it is essential to address any dents, nicks, or imperfections. Apply Putty Flex to fill in any imperfections and consider using mesh to reinforce big tears. Then, apply a generous coat of high-build primer surfacer to the entire surface. Allow the primer to dry completely, following the manufacturer's instructions. Once dry, sand the surface again with 320-grit sandpaper to ensure a smooth finish.
Painting:
Choose a suitable paint for plastic, such as spray paint, acrylic, or enamel. Common brands like Krylon, Valspar, and Rust-Oleum offer paints specifically designed for plastic. Apply an even layer of paint, ensuring not to apply too much in one area to avoid dripping. Allow the first coat to dry completely before applying the second coat. If using a single colour, sand the paint with 400-grit sandpaper after the final coat.
Clear Coat:
Once the paint is dry, apply a clear coat to protect the paint job and add shine. Don't forget to add a flex additive to the topcoat. Allow the clear coat to dry completely, and avoid touching or installing any components for at least a week to ensure it fully cures.
Additional Tips:
- Always work in a well-ventilated area to avoid inhaling fumes.
- Proper preparation is key to a successful paint job.
- Consider using a wrap instead of painting, as it may last longer and maintain the value of your ATV.
- If you are repairing cracks or damage, consider using a plastic welder or fusing technique before beginning the painting process.
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Frequently asked questions
You can use a plastic welder, which melts small metal stitches into the plastic. You can also use a soldering iron to stitch weld by melting the plastic back together.
You can drill holes on either side of the crack and zip tie it back together. You can also use glue, epoxy, or JB weld to repair the plastic. However, these methods may not be as strong as welding.
Work in small sections, especially on big cracks, to keep the plastic warm and ready to accept the weld. First, lightly fuse weld, then go over it again and melt the plastic directly into the weld.
You can rivet the plastic back together or use fiberglass mesh tape and fiberglass resin to repair it. You can also order new plastic parts, although this may be more expensive.
Make sure to work in a well-ventilated area, as the fumes from welding can be harmful. It is also recommended to sand and buff the weld to improve the appearance of the repair.
