Kia Carnival / Sedona (2006 year). Instruction — part 32

PP-4

PLASTIC PARTS

REPAIR METHOD FOR PP BUMPER

Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Use the repair methods
shown below to repair damage that reaches the surface of the polypropylene.

1.

Rough cut the damaged area 45 using a knife and then sand the angle smooth.

Hole

Section A-A'

Section D-D'

Section B-B'
Section C-C'

Crack

Scar

4

2

1

D

D

D'

D'

3

1

2

3

4

Upper layer (coating)
Primer layer

Primer surface layer
Polypropylene layer

VQPP002

C

C

C'

C'

B

B

B'

B'

A

A

A'

A'

Surface of polypropylene

A-A'
B-B'
C-C'

Angle of 45 is required for accumulation of polypropylene welding rod.

VQPP003

Cut with a knife.

Section

Section D-D'
Cut with knife.

Make an angle with a sander

.

45

Make an angle with a sander

PLASTIC PARTS

PP-5

2.

Welding damaged area
a)

To repair cracked area, melt the area using a heat gun and attachment.

b)

To repair a hole, remove oil from the damaged area and apply aluminum tape to the rear side of the damaged area.

3.

Melt polypropylene welding rod using a heat gun and fill in the cracked area.

NOTE

•

Heat and melt the area indicated.

•

Melt the welding rod carefully so that it does not over-melt. If the welding rod over-melts like jelly, the welding
strength will deteriorate.

•

Use the heat gun 0.4~0.8 in.(10~20 mm) away from the repair area to be welded.
Welding rod should not move until the welded area is cooled.

Heat gun

Apply on surface

Surface of polypropylene

Section view after melt

Melt the surface using a heat gun.

VQPP004

Remove oil.

Section A-A’

Apply aluminum tape on the rear side of the damaged area.

VQPP005

Melt here

Polypropylene
welding rod

Melt here.

Polypropylene
welding rod

A-A’
B-B’
C-C’

Section

VQPP006

Polypropylene welding rod

Tape

Plane view

Section A-A’

Polypropylene welding rod

Surface of
polypropylene

VQPP007

PP-6

PLASTIC PARTS

4.

Grind polypropylene surface carefully. It melts easily due to the heat generated by friction. If melted, remove that area.
Also, grind the area where solvent is to be applied.

5.

Apply polypropylene primer evenly with a brush over an area wider than the area to be repaired.
Dry it at 20 C (68 F) for more than 10 minutes.

6.

Mix main filler material and hardener at a ratio depending on paint specifications. Mix filler material and apply over the
damaged area.

NOTE

•

Mix main filler material and hardener so that no bubbles are made.

•

Work immediately after mixing filler material because the filler material hardens quickly(in about 5 minutes).

•

Dry it at 20 C (68 F) for about 30 minutes before sanding.

•

Filler material consists of two types of epoxy.
When the filler material hardens, you will have a desirable finish with flexibility like polypropylene.

•

Use only filler material designed for use on polypropylene bumpers.

Do not grind continuously.

Area to apply solvent

Paint

Grind painted area and rough surface.

VQPP008

Apply primer wider than the area to repair.

Polypropylene primer

VQPP009

Filler material

Weld

Surface of polypropylene

Do not allow bubbles to be created.

VQPP010

PLASTIC PARTS

PP-7

7.

Sand the damaged area with sandpaper using #180~#240 grit paper.

NOTE

•

The surface will not be even if excessive force is applied during sanding.

•

If there is fuzz in the damaged area, heat it a little bit with a heater gun and melt it.

8.

Degrease the painted surface.

9.

Mix polypropylene primer and hardener at a ratio depending on paint specifications.
Spray polypropylene primer on the surface of the damaged area and the bumper.

10. Apply polypropylene primer.

NOTE

Use only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.

11. Lightly sand the sprayed area using a primer a sandpaper(#400~#600).

The polypropylene surface should not be exposed.(Either wet sanding or dry sanding is all right.)

12. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil, and wipe the finished surface of the

bumper quickly with a clean cloth.

NOTE

•

The painting method for the polypropylene bumper is the same used to paint the urethane bumper.

•

Therefore, use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers.

13. Air dry at 20 C(68 F) for about 8 hours, or dry in 60 C(140 F) for about 2 hours.

(Since drying time varies according to the type of paint used, follow paint manufacturers directions for drying times.)

NOTE

Air dry if possible. Forced drying may create air bubbles on the top layer.

VQPP011

Use the primer within 16 hours after it is mixed.

Polypropylene primer

Primer hardener

VQPP012

7.

Sand the damaged area with sandpaper using #180~#240 grit paper.

NOTE

•

The surface will not be even if excessive force is applied during sanding.

•

If there is fuzz in the damaged area, heat it a little bit with a heater gun and melt it.

8.

Degrease the painted surface.

9.

Mix polypropylene primer and hardener at a ratio depending on paint specifications.
Spray polypropylene primer on the surface of the damaged area and the bumper.

10. Apply polypropylene primer.

NOTE

Use only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.

11. Lightly sand the sprayed area using a primer a sandpaper(#400~#600).

The polypropylene surface should not be exposed.(Either wet sanding or dry sanding is all right.)

12. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil, and wipe the finished surface of the

bumper quickly with a clean cloth.

NOTE

•

The painting method for the polypropylene bumper is the same used to paint the urethane bumper.

•

Therefore, use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers.

13. Air dry at 20 C(68 F) for about 8 hours, or dry in 60 C(140 F) for about 2 hours.

(Since drying time varies according to the type of paint used, follow paint manufacturers directions for drying times.)

NOTE

Air dry if possible. Forced drying may create air bubbles on the top layer.