Hyundai i30 / Elantra Neos. Body repair manual — part 40
PP-2
PLASTIC PARTS
POLYPROPYLENE(PP) BUMPER
REPAIRABILITY
The three types of damaged bumpers shown below can be
repaired. Because of cost and quality considerations,
bumpers with more damage may be repaired, but replacing
the bumper is encouraged.
1.
If a hole on a bumper is less than 2 in.(50 mm).
2.
If a crack on a bumper is less than 100 mm(4 in).
3.
If a crack on bumper sectionis [A] is less than 100
mm (4 in) (less than half of the bumper height).
A3EB3601
A3EB3602
Bumper height
Crack on section [A]
A3EB3603
PLASTIC PARTS
PP-3
BUMPER REPAIR PROCEDURE
Remove paint.
Sand damaged area smooth.
Apply aluminum tape on the rear
side of bumper.
Weld damaged area.
Sand damaged area with a rough sandpaper.
Clean and degrease damaged area(use TCE de-oil material).
Apply primer for polypropylene over damaged area.
Apply solvent over damaged area.
Spray primer surface over bumper and let dry.
Sand surface of bumper with sandpaper.
Clean and degrease with TCE de-oil material.
Wipe the surface of bumper with a tack cloth.
Paint bumper with a paint of the same color and let dry.
Surface of
bumper is not
visible.
Surface of
bumper is
visible.
Replace damaged bumper with a new
bumper.
Apply primer for polypropylene over
bumper surface.
VQPP001
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 10~20 mm(0.4~0.8 in) 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
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