DIY bumper hole repair

In detail: do-it-yourself repair of a hole in the bumper from a real master for the site my.housecope.com.

Having broken a plastic bumper on a VAZ car, the owner can relatively inexpensively purchase and install a new one, painted in a suitable color. Owners of foreign cars are not so lucky, plastic body kits for their cars are much more expensive. The way out is to repair the damaged part by repairing the crack with your own hands in order to save money. It is useful to know about the methods of restoring broken plastic to the owners of Russian cars, not to buy a new element because of small cracks.

Depending on the amount of damage and the type of plastic, the following methods of cracked bumpers are practiced:

cosmetic bonding with acetone and donor plastic;
gluing with modern chemical compounds;
mount on epoxy resin using fiberglass reinforcing mesh;
sealing the crack with a soldering iron reinforced with a metal mesh;
welding with a hot air gun and a plastic rod.

Reference. There is one simple method used by car enthusiasts who are not overly concerned about the look of the car. This is the connection of the edges of the crack with wire or staples from a stapler. This is a simple matter, which means that there is no point in considering this technology, everything is clear.

The use of acetone for bonding, which can dissolve many types of plastics, is a temporary measure used for small cracks that have appeared in the middle of the body kit. Its essence is as follows:

Pieces of plastic, similar in composition to the bumper material, are selected and dissolved in acetone to a thick consistency.
On the back of the bumper, the crack is degreased and also treated with acetone in order to soften the surface.
Liquefied plastic is applied to the damage from the reverse side, after which it hardens for several hours. Outside, the defect can be tinted with a corrector tube.

Video (click to play).

Any single cracks in most plastics can be sealed using thick two-component compounds sold in two tubes. The exception is fiberglass body kits, they are glued together with epoxy resin, and in case of serious damage, reinforcement with fiberglass mesh is used.

With numerous large cracks, breaks and holes in the bumper, bonding methods become ineffective. In such cases, soldering or welding with a hot air gun using a donor polymer material is practiced. After such repairs, the place of the defect is thoroughly cleaned and painted in the color of the car. Finally, a full bumper polish should be done so that the painted area does not stand out against the background of the old coating.

Advice. If you got into an accident or collided with a fixed obstacle and broke the body kit, try to collect all but the smallest pieces that have flown off. This will allow you to use "native" plastic for repairs and not look for something similar.

The preparatory process differs little for various methods of gluing and welding polymer parts, so it should be considered separately. The first question is whether it is really necessary to remove the bumper in order to make repairs. In most cases, dismantling is indispensable, since the plastic must be sealed on both sides. The exception is broken body kits, cracked in many places. They must first be stitched together and then removed. Otherwise, after repair, the part may lose its shape, which is why the attachment points will not converge, and the gaps with adjacent elements will increase.

Reference. Often, the body of the bumper comes off at the attachment points and small pieces of plastic remain on the screws.Before dismantling, such a part is securely welded to the torn mount and only then removed.

To prepare a damaged body kit for repair, you need the following tools and materials:

a set of keys and screwdrivers for removing the element;
electric grinder;
sandpaper of various grain sizes - from P180 to P320;
degreasing liquid - organic solvent or white spirit;
rags.

Note. With the help of a grinding machine, you can perform cleaning better and much faster than by hand. This and other power tools that are needed for painting and polishing can be rented for 2-3 days.

Regardless of whether work is being carried out directly on the car or with the bumper removed, it must be thoroughly washed and dried. Then, with a coarse sandpaper, you need to peel off the paint with an indent of 3-5 cm from the crack in each direction and sand the area with fine sandpaper. Whichever method of repair you choose, the paint must be removed to the base, otherwise it will interfere with the adhesion of the adhesive or the fusion of polymers during welding. At the end, the area should be degreased.

Advice. The quality of the body kit repair depends on the conditions in which it is made. It is more convenient to repair damage in a garage equipped with a viewing ditch for easy removal of a part and soldering of loose fasteners in place.

To implement this method, you need to purchase the following bumper repair kit from the 3M brand:

2 FPRM components for the preparation of liquid polymer in tubes of 150 ml (price - about 2500 rubles);
special hard tape;
self-adhesive reinforcing mesh made of fiberglass (otherwise - glass canvas) 48 mm wide;
an adhesion initiator in an aerosol can;
2 spatulas - wide and narrow;
stationery knife;
gloves, goggles.

Reference. Similar kits are offered by other manufacturers, but the 3M brand is the most famous and proven in practice.

Liquid resin bonding is suitable for most plastics and can be done either with the body kit removed or on the vehicle. True, the second option is rather inconvenient, plus you will need good lighting in the inspection pit. To cut the crack, you will need an electric drill (not a grinder!) With a mandrel for abrasive wheels. The repair consists of the following technological operations:

Important! After mixing the components, the composition must be used within 6 minutes, which is quite enough for applying to the damage on one side. A curing time of 30 minutes is correct for a room temperature of 21-23 ° C, therefore, when working in a cold room, it is imperative to arrange local heating of the bumper (for example, with an infrared heater).

If irregularities are noticeable on the front side of the element, then before painting, apply a little putty intended for plastic on the drops. After drying, clean it with P1500 sandpaper, degrease and paint with a spray gun, after applying a layer of primer. After 1 day, polish the surface of the body kit.

The technology is used to repair damage to body kits made of fiberglass, since the previous method will not work in this case. What is required for work:

fiberglass for bumper repair;
polyester (epoxy) resin complete with hardener;
soft brush;
utility knife or scissors;
latex gloves.

Advice. If a bulge or a depression has formed at the place of impact, then immediately after stripping, level it using a construction hair dryer to heat it.

Since fiberglass patches will have to be applied on both sides of the damaged area, it is better to dismantle the bumper from the car.After completing all the preparatory work, including stripping paint and degreasing, proceed in the following sequence:

Using a sander with coarse sandpaper (P80-P120), make a depression in the bumper body from the front side, covering a radius of 3-5 cm from the crack. This is necessary so that the fiberglass overlay does not ultimately protrude beyond the plane of the part.
On the back, sand it with a coarse sandpaper, but without a depression. Degrease the area and let dry.
Cut out the fiberglass patches. On the front part, you need to make a neat patch, repeating the shape of the recess, and from the rear you can glue a rectangular overlay.
Mix resin and hardener in the proportions indicated on the package. Apply the composition with a brush to the surface, apply a patch (you can in several layers) and saturate it with resin.
Accurately observe the time specified for the curing of the epoxy compound (written on the container with the resin), then carefully clean the repair area with a fine sandpaper. The task is to level the surface by removing the protrusions.

Note. Initially, coarse sandpaper is used in order to create a roughness on the surface of the plastic, which contributes to better adhesion of the polyester adhesive.

This completes the work on the repair of the plastic itself, then cleaning, priming and painting are performed using standard technology. The last operation is bumper polishing, it is necessary to give the element a uniform shine.

Numerous cracks, breaks and torn off bumper elements are repaired using thermal methods, in particular, soldering. This painstaking work requires a small set of tools and materials:

a soldering iron with a power of at least 100 W with a wide sting and a wooden handle;

thin metal mesh specially designed for thermal bonding of plastic parts;

knife, nippers for processing broken off segments;

screw clamp;

fine and coarse sandpaper for cleaning seams.

Note. Soldering of serious defects can take hours. During this time, the plastic handle of the soldering iron will warm up so much that it will become difficult to hold the tool with your hand.In the process of preparing for soldering, the paint must be removed to the base not only from cracks, but also from torn pieces of the bumper. Moreover, in this case, the body kit is not removed from the car until all the gaps are fastened and fixed by soldering, otherwise the element will lose its exact shape.Soldering technology is implemented in the following sequence:Important! When soldering the edges of the plastic, you need to hold it motionless and give time to solidify. If you release the part ahead of time, the seam will come apart.At the end of the soldering procedure, sand the surface of the element, then degrease and paint in the desired color. During further operation, be more careful, because from a strong impact, the bumper can fly to pieces, breaking in the same places. To hold it together more firmly, it is worth using another method - welding with donor plastic.

The bumper is a safety feature of the vehicle that also has aesthetic functions, enhancing its appearance. In accidents, in collisions, the part takes on the force of the impact, protecting the body and passengers. Damage also occurs in other situations - when parking, maneuvering.

The cost of subsequent restoration is determined by the degree of damage. But knowing how to repair a plastic bumper yourself, it is easy to cut costs and not leave the car in service.

Work begins with an inspection of the damaged bumper, assessment of defects and the feasibility of restoration. If the damage is accompanied by the loss of pieces, the procedure becomes more complicated - you need to choose the same material to fix the hole or order a new bumper.

The repair technology is determined by the existing defects:

Scratches, chips that have not touched the plastic are removed by sanding, putty and subsequent painting.
Deformations are common damage, often accompanied by cracks. To restore the geometry, the part is heated with a hairdryer; a burner will do. Heating the plastic makes it soft and pliable. Then it is easy to give the element the desired shape. The result is recorded until it cools completely. Do not overheat the fragment. This is accompanied by thermal deformation.
Cracks are common damage that requires soldering. Depending on the size of the crack, its location, reinforcement, reinforcement, contraction may be required to prevent further divergence.
Holes are flaws that arise when you hit an obstacle or as a result of a collision with the back of another car. Occur as a result of the effect of the muffler. Self-repair involves soldering, reinforcement. The procedure is possible if there is a missing element. If a selection of material is required, the markings on the inside of the bumper are preliminarily examined.

With the right approach, it is easy to eliminate damage, the main thing is to follow the sequence of stages, technology, and prepare a place for work.

Plastic bumper soldering options

Soldering is an effective method of repairing cracks and holes in a plastic bumper. When thinking about how to solder the bumper yourself, it is better to carry out manipulations from the front side. It is important to solder to the correct depth. Working from the inside, it's easy to make mistakes. Then putty, paint layer will crack soon.

Preparatory steps:

The bumper is being dismantled or the undamaged elements of the car are protected.
A table and a workplace are being prepared. If the part turns over to the front side, the surface is covered with a soft cloth.
At a distance of 1 cm from the edges of the defect, paint is removed.

Bumper soldering options:

The soldering iron heats up, after which notches are made from each edge of the crack. The tool is deepened by half the thickness of the element, held at a 45 degree angle. A comb is obtained at the edges. Further, a soldering iron tip is carried out along the crack, smoothing it. The edges are securely connected.
Using staples from a stapler allows you to get a reliable connection if the material is thin. Staples, in steps of 3-5 mm, are fused into the plastic, the ends are bent from the inside. They shouldn't stick around.
Copper and ordinary wire, as solder, allows you to securely hold the elements together. Skills and experience are required here. Small holes are needed for threading the wire. The further scheme of work does not differ from the use of staples. For minor damage, holes are not made.
The plastic solder helps create a solid surface. It is supposed to be restored by adding plastic in the place of damage. It is important to find the right solder.

Reinforcement of the structure

Brazing is the most effective method. But so that the crack does not reappear, the place of damage is reinforced. Further processing uses fiberglass, epoxy, rubber glue. Over time, materials move away without violating the integrity of the structure. Therefore, they are applied from the inside.

In the area of damage:

- the paint is cleaned;
- the plane is degreased;
- glue is applied;
- mesh, wire is applied;
- alternating a layer of fiberglass and glue, which will be the final one.

Regardless of the choice of soldering and reinforcement method, the process ends with grinding the cooled surface, putty until a flat plane is obtained.

Important points in preparation for painting

Eliminating defects is only part of the job. For a complete restoration, you need to know how to paint a car bumper correctly. The process starts with preparation. If the part is soldered, the work area should be carefully sanded, as if there are scratches.

Putty is carried out in several stages:

a special putty is applied to work on a plastic plane;
such a height is gained so that the putty protrudes a little;
the area is sanded until all irregularities are eliminated, which are checked by touch;

The procedures are repeated until an ideal plane is obtained. When preparing yourself, it is better to choose fine sandpaper. The next step is degreasing. Apply the primer twice, ensuring that each layer dries.

The moment of preparation implies not only the surface treatment of the element.

the place where the work will be carried out must be cleaned, wet cleaned, dust removed;
walls, ceiling, floor covering are cleaned.

it is better to dismantle the bumper, which will ensure a high-quality application of the paint and varnish layer;
if dismantling is excluded, the car is tightened with film.

Selection of paint:

the best option is by VIN-code, then the color match is guaranteed;
computer selection is also effective, but some differences cannot be ruled out.

Paint application, preparation of materials:

the amount of paint, its composition, the method of application determines the quality of coloring, the final shade, consumption;
the spray gun needs to be set up correctly, make sure that the pigment supply is normal (if an aerosol is not used).

Secrets of painting technology

Correct painting of a bumper is a simple procedure, provided it is properly prepared. In work you need to use a mask. The amount of materials and the time required for painting is determined by the amount of work.

Types of painting:

Local painting is suitable for inconspicuous areas, lower elements, when damage is minor or scratches on the bumper need to be painted. It is supposed to apply paint to a specific area.
Full bumper painting is used for damage in conspicuous places.

The painting process includes the following stages:

Blowing, degreasing.
Testing paint on parts, applying a small amount.
The first layer is made thin - this is the base. Dries 5 - 10 minutes.
Apply 2 coats of paint with drying intervals of 15–20 minutes.
If dust gets on the part between layers, special interlayer wipes are used to remove dirt.
The final stage is the application of 2 layers of varnish with drying.

With unhurried preparation, careful application of pigment and varnish, irregularities and streaks do not occur. But if defects appear, you need to wait until the element is completely dry, and then grind and polish these places.

Often in the traffic flow you can find a car with a cracked or deformed buffer. What can you do, no one is safe from unsuccessful parking or a minor accident. Nevertheless, this is not a reason to continue driving a car that has lost its "shiny" appearance - there is a practical experience of restoring the original state of this element.The external plastic components are mainly made of thermoplastic plastics. The technology for restoring such products is based on welding, it is this technology that allows you to get rid of through cracks and even recreate broken fasteners. Actually, the procedure is not much more complicated than preparing and spray paint damaged area of the car body.Some car enthusiasts assure us that we repair the bumper with our own hands using metal brackets. But the experienced car owner knows that like is treated like this, that is, repair plastic rods are used for soldering. Their composition, color and profile are different; the required core is selected according to the marking on the buffer.Making the right choice means guaranteeing a high-quality repair, because the mismatch of materials will significantly reduce the life of the automotive element. To find out what the cracked bumper is made of, it is enough to carefully examine the inside of the part. Depending on the marking, appropriate conclusions are drawn:

PP - polypropylene base.

ABS (GF, PAG 6) are hard plastics.

PUR - polyurethane.

Plastic welding requires high temperatures, for example, 400-450 ° C is suitable for propylene, and 500 ° C is necessary to restore an ABS structure. Many car owners will learn how to repair a bumper with their own hands in a video where craftsmen use an ordinary 100 W soldering iron.You can also restore a damaged part using pieces from a bumper with a similar marking. They are cut into strips 8 mm wide for PUR, and 4-5 mm for polypropylene.Almost any breakdowns are treated by welding, even broken parts are reanimated. However, no one canceled the economic feasibility of such work, because the restoration of numerous defects can hardly be called justified. The cost of a complete restoration and staining will be more expensive than a new buffer.Certain tools are required to complete the repair. These can be both ordinary household appliances and professional tools. The ideal kit includes the following items:

Orbital sander or sanding block.

Grinding wheels of various grain sizes.

Mini drill like Dremel or drill.

Clamps and rubber spatula.

Soldering iron and hair dryer.

Metallic tape.

Of the materials for restoring a cracked buffer, you may need:

Putty and primer.

Brass mesh for crack reinforcement.

A can of paint or a can of paint.

Plastic repair rods of the required configuration and composition.

The damaged part must be dismantled in order to eliminate, firstly, excessive stress in the crack area. Those who have already done such work will say that now we clean the bumper and only then repair it with our own hands.The cracked parts fit together. For reliability, they are fixed with metal tape from the outside of the part. If the breaks are quite significant, then clamps will be needed to clamp the edges of the cracks. Their number depends on the complexity of the repair.When restoring PP-based parts, the reinforcing mesh is not used. The process begins with the fact that a nozzle with a nozzle with a diameter of 5-7 mm is installed on the hair dryer. In the future, work is carried out according to the following points:

On the inside of the buffer along the crack joint, use a Dremel mini-drill to make a groove for the plastic rod.

Using a hair dryer, melt and place the repair rod into the prepared groove.

Clean the front part of the bumper with an orbital sander with P240 attachment and repeat the welding procedure similarly to the operation on the inside.

Grind the cooled seam from the outside with a nozzle with the same grit P240, then remove dust from the surface.

Even out irregularities with a special putty for plastic, try to keep the layer as small as possible.

Dilute the primer with solvent 3: 1 and apply two coats to the degreased surface. Drying time for the first layer is 15 minutes.

Apply a developing layer in a contrasting color, followed by sanding with a disc or sandpaper with grit P800 and P1000.

Eliminate the detected defects with a nitro putty followed by sanding with P1000 sandpaper.

Remove dust with a damp cloth and degrease the part, then paint plastic decorative paint with overlapping borders 50-100 mm. Apply the paint in 3-4 coats with intermediate drying cycles.

Anyone who is interested in how to properly repair a bumper in a video with their own hands should take into account an important detail. 30-40 minutes after applying the last layer of paint, the part should be varnished. Thus, we get a flawless appearance of the repaired part. Do not forget to follow a few simple rules:

You should try to apply a minimum layer of putty.

Take a temporary pause for complete hardening of the putty layer.

To process the putty area with a grinding wheel or sandpaper with grit P800, and then - P1000.

It is desirable to apply a developing layer of primer.

In the case of a polyurethane buffer, the preparatory stage in the form of grooving work is excluded. A brass reinforcing mesh is applied to the crack; steel is not recommended for use, because it is prone to corrosion. Alternatively, stapling staples can be used every 10-20 mm. They are recessed into the body of the part across the seam, it is imperative to make sure that the bracket does not go through the part.Further, the repair technology does not differ from the restoration of a polypropylene part. Wire mesh or staplers should be sunk into the plastic. Only after that, the seam is filled with repair plastic and soldered from the opposite side. Some important points of technology should be taken into account:

It is necessary to solder the mesh or staples carefully so as not to overheat the plastic, otherwise it may deform from the opposite side.

For a complete DIY repair of a polyurethane bumper, the width of the reinforcing mesh should be 15-20 mm.

It is better to press in the mesh or staples with a flat object.

If the legs of the staples pierce the plastic through and through, then they should be shortened using side cutters.

For the convenience of working with metal elements, you can use tweezers.

To prevent the new enamel from peeling off, it is necessary to grind the paint over the entire plane of the part.

Puttying and painting are performed in the same way as described above - according to the traditional scheme. Repair work on the restoration of the buffer can be combined with painting the car , so the consumption of materials will be more rational. It is important to determine in advance the feasibility of carrying out restoration work. If there are significant costs in the future, then it is better to buy a new part.According to generally accepted safety standards, each vehicle should be equipped not with metal bumpers, but with their plastic counterparts. When hitting a pedestrian, the plastic bumper cushions the force of the impact to a large extent.Thanks to this, the pedestrian has a chance to stay alive and not get dangerous injuries (of course, provided that the speed of the car was not very high).In addition, the use of plastic bumpers significantly reduces the overall weight of the vehicle, which has a positive effect on overall agility and dynamics. However, the main disadvantage of a plastic bumper is considered to be its weak shock resistance.To all of the above, we can add the fact that some car manufacturers are simply trash when making bumpers. They make them out of very thin plastic. Therefore, even a weak blow provokes the appearance of all kinds of cracks and holes.As a result, the car owner has to do the repairs more often than he would like. All those who have already encountered this nuisance are well aware that such repairs in any car service are not cheap. In some cases, it is easier to buy a new part, but there are amateurs who prefer to do everything with their own hands. This article was written for such beginners Kulibins.In fact, all actions to restore a problem bumper are not difficult at all, provided that the hands grow as they should :). Therefore, let's look at how to do everything without outside help.First, let's say that according to statistics, car owners are much more likely to restore the front bumper of their vehicles than the rear one. This is explained by the fact that the front bumper is more often subjected to mechanical damage: collisions on the curb; impacts in case of accidents; damage that occurs when stones or other objects hit.First of all, it must be said that there are several ways to repair a bumper. First of all, the types of repairs are subdivided according to the nature of the damage:

chips, dents, scratches without through damage

cracks

loss of a bumper fragment

If the bumper has retained its integrity, then consider yourself lucky. Repairing chips and scratches is the simplest type of repair, which boils down to cleaning the chip area with sandpaper, filling the damaged area, sanding and painting.What you should pay attention to when performing these operations, we will consider further when describing other types of repairs, since all these operations will be present in almost all types of bumper repairs.For the sake of fairness, it should be noted that many motorists do not even repair chips and scratches, but drive with these damages until they decide to sell the car.But the cracks can no longer be ignored ...Cracks are the most common problem with plastic bumpers. A timely untreated crack can further cause complete destruction of the bumper. Therefore, try to immediately repair cracks, and not wait for the right moment.First of all, it should be noted that today there are quite a few ways to repair cracks on the bumper.Special repair kits are sold and the method to choose depends on various factors: on the type of plastic from which the bumper is made; from the tools at hand; from the skill of a motorist in repair; from the time allotted for repairs.So, for example, in conditions when there is no time for repairs at all, and you need to come up with something very quickly, then you can even seal the crack with plastic clamps.For repairs in this case, you will need a drill, a set of plastic, narrow clamps, a drill.To begin with, the edges of the crack are drilled to prevent its further spread. And then, on both sides of the crack, paired holes are drilled through which a plastic clamp is pulled and tightened from the inside of the bumper.Such screeds must be made along the entire length of the crack at a distance of 1.5 cm from each other.Of course, such a repair does not look very aesthetically pleasing and can be used as a temporary way out of the situation before replacing the bumper.It is, of course, also possible to overhaul the bumper, after which the repaired part will outwardly be indistinguishable from the new one.There are also several options for this repair, but all of them are united by one principle: first, the crack is eliminated with simultaneous reinforcement, and then the seams are sanded and painted.The crack can be closed by soldering, gluing, screed with construction staples, special electrodes, metal mesh, etc. A combination of different methods is also possible.Here we will consider one of the options for repairing a cracked plastic bumper ...First, it is required to dismantle the damaged bumper from the car. Typically, the bumper is secured with one bolt on the right and left sides in the inner section of the wheel arch (where the bumper connects to the fender) and four bolts in the center (along the top and bottom edge of the bumper).Next, we begin the procedure for restoring the bumper. First, you need to carefully drill the boundaries of the crack with a small drill so that it does not spread further. Then, to increase the integrity and strength of the structure, a small metal mesh is soldered onto the inner surface of the bumper (on the crack section itself). During this process, it is necessary to solder it as deeply as possible into the plastic, but at the same time not to solder through the bumper itself. This procedure can be done with a 60W soldering iron.On the outer part of the bumper, we clean the damaged area from the paint, we also solder the crack, but without the mesh. We do this very carefully. Then we clean the seam. We remove dust from the surface. With a construction hairdryer, we burn the villi, which will most likely appear on the plastic after cleaning, and then apply a thin layer of putty. We are waiting for the putty to dry, and then carefully clean it.Next, we paint the bumper. The bumper should be painted in thin layers with the obligatory drying of each layer within 30 minutes.A minimum of five coats of paint are required. Then the painted area must be polished so that it acquires the desired shine, and its shade becomes identical to the color of the entire bumper. We advise you to polish first the place that was repaired, and only then the entire bumper. That's all, we can install a bumper on the car.If holes appear in the bumper or pieces of plastic have fallen off, then take your time to buy a new one. These damages can be easily repaired. In addition, all this can be done by hand.As in the previous case, remove the damaged bumper. Next, you should clean the damaged area from the remnants of paint. Then, on the inside of the bumper, you need to glue cardboard, which will replace the rear wall and prevent the repair mixture from spreading (when we will make the "build-up" of the bumper).Next, using epoxy, fill the damaged area with it and let the mixture dry well. After that, we carefully grind and prepare for the application of the putty. Then slowly and very carefully remove the cardboard and putty the problem area from the inside.As in the first case, after covering with putty, we perform painting and polishing procedures, and then we install the bumper in its rightful place.