Repairing a Long Tear on a Bumper Cover

Repairing a Long Tear on a Bumper Cover


The length of this video is in no way indicative
of the amount of time it takes to perform this procedure. It should therefore not be used for estimating
purposes. This bumper has a long tear that many would
consider to be beyond repair. In reality, this is the type of repair that
technicians will look forward to tackling with the help of an arsenal loaded with tools
and supplies from Polyvance. Begin by stapling the tear back together using
a 6023 cordless plastic stapler. If the plastic isn’t perfectly flush, you
may need to shave it down using a razor knife. Then apply additional staples as necessary. Apply aluminum tape. Because we’ll be performing a backside weld
for the first part of this repair, we will tape the front. Grind v-grooves along the cracks using a 6125
tapered burr. Rough up the plastic surrounding the crack
using a 36 grit roloc disc. You may now begin welding. Here, we’re using a one-eighth inch round
welding rod. Continue welding. As you move on, be sure to use your best judgement. For tears such as this, it is not uncommon
to need to apply additional plastic. As many as second or third passes with rods
varying in width may be necessary to cap this repair. Adding a “T” to the outermost points of the
crack will provide a great deal of extra strength. Smooth the welded area using hot nitrogen
gas and the airless welder. After the weld is completed, it should look
something like this. We are now ready to begin our finish work. Spray the front side with 1000-A Super Prep
Plastic Cleaner and scrape off the adhesive residue left behind by the aluminum tape. You’ll have to repeat this process as many
as three or four times to get the plastic completely clean. Now it’s time to remove the staples. Carefully heat each staple using the nitrogen
welder and then gently pull them from the plastic using pliers. Take care not to overheat and distort the
plastic. V-groove the front side of the bumper again
using the 6125 tapered burr. Repeat the welding process. Rough sand to profile using 36 grit sandpaper
on an 8 inch sander. Then again using 80 grit. Now we’ll remove the fuzz that was left over
from the sanding process. Using a torch, carefully singe the sanded
area. Keep the torch in constant motion so you don’t
overheat the plastic. In addition to removing the fuzz, this method
also drastically increases the adhesion of coatings to the bumper. Apply 1050 Plastic Magic adhesion promoter
and allowed to dry. Apply Putty Flex and allow to cure. Sand the filler down using 80 grit sandpaper. Block sand using 80 grit, and then sand again
using 180 grit. Spray the entire repair area again with 1050
Plastic Magic adhesion promoter. Prime. Hand sand using 320 grit sandpaper, and then
add a final coat of primer. As you can see, intense tears like this may
be intimidating but are well within the means of any technician using tools and supplies
from Polyvance. Look to Polyvance for all of your plastic
repair product and training needs. We offer I-CAR Industry Training Alliance
courses as well as other hands-on classes in addition to the video resources you can
find on our website and on our YouTube channel.

8 thoughts on “Repairing a Long Tear on a Bumper Cover

  1. First off bumpers do not match cars. You have developed these products to save insurance companies money. Well they also save money by not blending a car for bumpers..Secondly just as your tools are expensive to save these parts we have expensive cameras to match paint so that we can match colors.

  2. Nice repair lads.
    I am from the U.K. And have just had a demo on a nitrogen welder, it generates its own nitrogen so no bottle is required, very nice bit of kit.
    I have watched a lot of your videos, one thing puzzles me, why must one v groove the rear side of the repair ?
    I can see the point of v grooving the front side.

  3. Another great video… I thought for sure you were going to use the stainless steel mesh. But I guess you want to keep the flex and rigidity of the bumper. Great fuzz/torch method. I use to go crazy trying to sand them out.

  4. Visit this video page on our website to see the full list of products used and other helpful tips: https://www.polyvance.com/video/nitrogen-hot-air-welding/repairing-a-long-tear-on-a-bumper-cover

  5. That nitrogen welder is like $1000. When using the plastic tubes what other thing can I use to melt it? Or can I use the flat hot iron it supplies in the kit to melt the tube into the bumper?

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