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repairing broken tabs

REPAIR STEP

3

Page 12

www.urethanesupply.com

Repairing Flexible Tabs on TEO Plastics

  • Many TEO bumpers have mounting tabs that have to flex during installation. These can be repaired very durably with the mesh and FiberFlex. First, rough grind the area with a coarse Roloc disc.

  • Cut 2045W Stainless Steel Wire Mesh to size to fit in the corner areas on both sides of the tab. Using the hot welder tip, bury the mesh directly into the plastic. After you’ve melted the mesh into the plastic, scuff the melted plastic with coarse sandpaper to remove the gloss.

  • Melt on a thin layer of FiberFlex over the mesh just to cover. In this repair, the mesh provides the strength and flexibility while the FiberFlex just gives a cosmetic covering.

Repairing Torn Tabs

  • Rough grind the area surrounding the crack with a coarse Roloc disc.

  • Cut 2045W Stainless Steel Wire Mesh to size to fit in the corner areas. Using the hot welder tip, bury the mesh directly into the plastic. (This won’t work on urethane parts since they don’t melt. See Page 5). After you’ve melted the mesh into the plastic, scuff the melted plastic with coarse sandpaper to remove the gloss.

  • Melt either the FiberFlex or the matching standard plastic rod over the mesh. If using the standard rod, keep the heat on the plastic to make sure the rod melts thoroughly with the base material. Keep adding more rod to make a bigger fillet and increase strength.

repairing broken bolt holes

REPAIR STEP

3

There are many cases where the only damage on the part is a torn-out bolt hole or a broken-off tab. The welder is great for repairing such damage. Here are a few strategies for fixing the most common damage found on plastic parts.

Repairing Torn Bolt Holes in TPO with FiberFlex

2

3

• Melt 2045W Stainless Steel Reinforcing Mesh into the plastic across the gap if desired for extra strength. This step is often not necessary because FiberFlex is blended with glass fibers for strength.

• Allow FiberFlex to cool completely. Open the hole with a die grinder or drill bit, then sand with 80 grit in a DA at low speed to finish the repair.

1

  • Taper both side of plastic to a point with a coarse Roloc disc. Grind and taper around the edges of the entire bolt hole. Taper back about 1 inch on all sides. Remove paint and radius into taper with 80 grit in a DA.

  • Apply 6481 Aluminum Tape across the gap to support the melted rod while it’s hot.

  • Apply FiberFlex to area using the instructions on Page 7. After cooling, remove aluminum tape and repeat on opposite side.

applying epoxy filler

REPAIR STEP

4

  • Grind area to be filled with coarse sandpaper. Slightly v-groove away from the damaged area. All gloss on the surface should be removed to maximize filler adhesion.

  • If the material is a polyolefin (PP, PE, TEO, or TPO), apply 1060FP Filler Prep Adhesion Promoter.

  • Choose a two-part epoxy filler to match the hardness of the substrate. If flexible, use 2000 Flex Filler 2. If rigid, use 2020 SMC Hardset Filler.

  • Mix epoxy adhesive in equal parts and apply. Build up slightly higher than the surface to allow for sanding. Allow at least 20 minutes to cure before sanding. Contour and smooth the surface with 80 and 180 grit paper.

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