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REPAIR STEP

3

repairing living hinges and tabs

800.633.3047

Page 13

Repairing Living Hinges on TEO Plastics

  • One of the most difficult tabs to repair are those which are designed to flex along a “hinge” line. The 5010-1 polypropylene sheet was devel- oped to perform such repairs on TPO bumpers.

  • If you have a good tab left to trace, begin the repair process by tracing the tab onto the 5010-1 PP sheet using a marker or a razor knife. If you have no tab to trace, create a cardboard template for the tab, then trace the template onto the plastic sheet. When making the new tab, be sure to leave an extra strip of plastic past the hinge to allow a place to weld in the new tab into the bumper. Cut the tab out of the polypro- pylene sheet using a jigsaw or hacksaw.

  • To make the “living” hinge, clamp your tab into a vise along the hinge line, then bend back and forth to make the hinge line flexible. If the final shape of the tab has an “L” shape, bend this area only one way to keep it stiff.

  • Cut a notch in the bumper to receive the new tab. Trim the tab or bumper as needed for a snug fit.

  • Hold the tab in place using 6481-2 foil tape. Weld the tab onto the bumper using R13-W PP strip welding rod and a hot air welder.

  • While still hot, burnish the R13-W strip into the tab and bumper using an airless plastic welder with the 6028RT tip. Let cool, then repeat the same procedure on the opposite side. Once cool, the tab should be a least as strong as the original.

  • Finish the repair by sanding the welded area slightly flush, then fill with 5003R10 FiberFlex. Allow to cool, then finish sand.

REPAIR STEP

5

retexturing plastic

Using 3800 Flex-Tex

    • Scuff Sand - After repairing the damage, scuff sand the area you intend to retexture with 320 grit paper and blow dust free.

    • Decide How to Blend Texture - Check the grain, texture, and contours of the panel to be repaired. It is not necessary to exactly duplicate the existing texture to achieve a quality repair. You may be able to blend the new texture out into the old or retexture to a natural break line in the panel to avoid having to retexture the entire panel.

    • Mix Texture Material - Stir 3800 Flex Tex flexible texture material and pour into a primer gun with a 1.8 - 2.0mm nozzle. Spray some test patterns on a scrap piece of paper and dial in the size and grain of the texture by adjusting the speed of the pass, the air pressure, and the fluid flow. A lower air pressure will give you a larger grain.

  • Apply Texture Material in Light Coats - When applying Flex Tex, hold the gun about 18 - 24 inches from the surface. Apply in light coats and allow flash time between each coat. Do not wet spray the material as it will flow out and destroy the grain effect. It may require as many as 8 - 10 light coats to achieve the necessary buildup.

  • Nib Sand and Blend Texture - When the desired texture buildup is achieved, allow the texture to dry completely. Then, using a scuff pad, lightly nib sand the newly textured area. As you nib sand you will detect the repair area begin to blend into the original texture of the panel and the sprayed look will disappear.

  • Apply Flexible Color Coat - After sanding the texture, blow dust free and apply a flexible color coat. To match over 40 OEM shades of gray, topcoat with 3500 series Bumper and Cladding Coat Paint.

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