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Repair Method E: Epoxy repair



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Repairing Plastics with Epoxy Based Adhesives

  • Sand backside of area to be repaired with 50 grit paper or coarser. Heavy grooving of the plastic is desirable to maximize the mechanical strength of the bond. Afterward, sand lightly with 80 grit for finer grooving which will further improve adhesion.

  • If the material is TEO, TPO or PP, you must apply 1060FP Filler Prep Adhesion Promoter. Brush onto the sanded area and allow to flash off.

  • Apply 2044-2 Fiberglass Reinforcing Tape over the damaged area. If part is SMC, cut a backing panel from a scrap piece of SMC. Make sure the backing panel extends at least 2” beyond damage in all directions.

  • Choose a two-part epoxy adhesive system to match the hardness of the substrate.


2000 Flex Filler 2 (gray)


2020 SMC Hardset Adhesive Filler (gray)

  • Mix epoxy adhesive in equal parts, apply over fiberglass reinforcing tape on backside of repair. Allow 15 minutes to cure before handling. On SMC, apply a bead of 2020 SMC Hardset Filler to the backing panel and press into place. Allow epoxy at least 20 minutes to cure before handling.

  • Sand front side of damaged area with 50 grit paper or coarser and v-groove away from tear. The deeper and wider the v-groove is, the stronger the repair will be. Remove paint in the surrounding area and radius into the v-groove with 80 grit in a DA.

  • Again, if the material is a TPO or PP, apply 1060FP Filler Prep Adhesion Promoter.

  • Mix and apply selected epoxy adhesive. Build up slightly higher than the surface to allow for sanding. Allow at least 20 minutes to cure before sanding. On SMC, layer pieces of 2043-U Uni-Cloth fiberglass cloth into the v-groove between coats of epoxy. Use a saturation roller if necessary to fully wet the cloth with epoxy.

  • Contour and smooth the surface with 80 and 180 grit paper.

Repair Method F: Insta-Weld repair



Repairing Plastics with Insta-Weld Adhesives

Our line of Insta-Weld adhesives are specially formulated to provide maximum adhesion on a wide variety of common automotive plastics. Because Insta-Weld forms rigid bonds, it works best with rigid plastics like ABS, polycarbonate, and SMC. It may also be used to tack parts together while performing a welding repair.

Fixing Cracks Quickly

  • Prior to assembling parts, lightly spray area to be bonded with 2303 Insta-Weld Activator.

  • Assemble and align parts. Use clamps or 6481 Aluminum Body Tape to hold parts together while bonding.

  • Apply a small amount of 2200 Insta-Weld 1 thin adhesive to the joint or crack. Optimum results are obtained with the minimum quantity of adhesive needed to fill the joint. The adhesive is thin enough to allow it to be wicked down into the crack. Use 2250 Insta-Weld 2 thick gap-filling adhesive for parts that do not fit together perfectly.

  • Spray on additional 2303 Activator to complete the cure. Additional Activator and Insta-Weld 2 may be applied to fill any small remaining gaps.

Filling Gaps, Holes, and Gouges

  • Use 6481 Aluminum Body Tape as a back-up under the hole.

  • Rough sand and v-groove area around the hole and blow dust free.

  • Spray a light coat of 2303 Activator in and around hole.

  • Fill hole with 2300 Weld Compound and saturate with a few drops of 2200-1 Insta-Weld 1. Smooth and saturate the Weld Compound with Insta-Weld using a disposable tool if desired. Wait 5 or 10 seconds and apply another light coat of 2303 Activator. The repair may be sanded or drilled immediately.

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