Ford Falcon. Manual — part 490
501-25C-1
Body Repairs — Plastic Repairs
501-25C-1
SECTION : 501-25C Body Repairs — Plastic
Repairs
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
DESCRIPTION AND OPERATION
Plastic Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...501-25C-2
Plastic
Idendification
. . . . . . . . . . . . . . . . . . . . . . . . . . ..501-25C-2
Plastic Bumper Repair . . . . . . . . . . . . . . . . . . . . . . . . . ...501-25C-2
501-25C-2
Body Repairs — Plastic Repairs
501-25C-2
DESCRIPTION AND OPERATION
Plastic Repairs
Plastic Idendification
Automative uses include heater assemblies, batteries,
Item
Description
fan shrouds, headlight bodies and kick panels.
1
Cowl Grille PP
ABS (Acrylonitrile Butadiene Styrene)
2
Door Handle PA66
3
Mirror ABS/PC
This material is stiff, hard, easily cut with a sharp
knife, sinks in water and burns readily with an
4
Splash shield PP
orange/yellow flame (similar to an acetylene flame)
5
Bumper cover PP
with black smoke and soot flakes.
6
Headlight lens PC (coated)
Widely used in the motor car for radiator grilles, tail
NOTE: All plastic parts have material idendification
light bodies, interior and exterior trim panels.
codes (Recycling Codes) acoording to SAE J1344.
Plastic Bumper Repair
PC (Polycarbonate)
Polypropylene Bumpers
A stiff hard metarial that is not readily cut, sinks in
1. Cut the rough edges around the flaw with a knife
water,difficult to ignite but burns with an orange
to make it smooth. Sand the area with a sander to
spluttering flame and yellowish sooty smoke, and
make an angle of about 45 degrees.
sweetish smell when extinguished.
CAUTION: Disconnect the battery ground
In the automative trade, Polycarbonate is blended
cable before using any electric welding
with other thermoplastics to produce alloys.
equipment.
PP (Polypropylene)
2. Weld damaged area. For service to a cracked
Stiff, hard, easy to cut, has waxy almost greasy feel,
area, melt the crack together using an Airless
floots in water,burns with a yellow flame with a trace
Plastic Welder. For repair of a hole, degrease the
of blue at the base of the flame, molten droplets, little
area and the reverse side of the damaged area.
smoke and smells of burning oil when extinguished.
Install aluminium tape on reverse side of,
damaged area.
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501-25C-3
Body Repairs — Plastic Repairs
501-25C-3
DESCRIPTION AND OPERATION (Continued)
3. Melt the polypropylene welding rod with the
a urethane bumper and polypropylene primer for
welder and deposit it in the cracked area. Take
a polypropylene bumper.
care not to excessively melt the welding rod. If the
part is welded with the welding rod melted like
jelly, the welding strength will be lowered. Operate
a heat gun 12-51 mm away from the part that will
be welded. Do not move the welded rod until the
welded part cools.
NOTE: Do not sand part continuously.
4. Sand the surface of the polypropylene little by
little, since it is easily melted even by the abrasion
heat. If melted, remove the melted area. Sand the
areas to which service agent will be applied.
5. Apply polyproplene primer uniformly to an area
larger than the serviced area with a brush. It will
take about 10 minutes to dry at 20
°C.
NOTE: When mixing the main and stiffering
agents,be careful not to allow bubbles to form.
6. Mix the main agent and the stiffering agent in a
ratio of one to one. Apply the mixed service agent
to the demaged area.Since the servicing agent
hardens fast (about five minutes), proceed with
the work immediately after mixing the agents. It
will take about 30 minutes to dry at 20
°C before it
can be sanded.
NOTE: If excessive force is applied to the area
when sanding, the surface will not become
smooth.
7. Sand the area with # 180- # 240 sandpaper. If
there is fuzz around the repaired area, melt it by
heating it slightly with a heat gun.
8. Degrease the painted surface.
Item
Description
NOTE: Polyproplene primer will dissolve, even
1
Front bumper absorber
after drying, if it is wiped with solvent. Use only
2
Front bumper retainer
water to clean.
3
Front bumper cover
9. Dry the part.
4
Front grille
10. Add the softener to the urethane primer surfacer
5
Front lower valance panel
and spray it on the service area.
6
Lower air deflector
11. Air dry at 20
°C for 8 hours. Force dry at 60°C for
1 hour.
12. Lightly sand the area on which the primer surfacer
is sprayed and the complete surface of the
bumper with #400-#600 sandpaper.Do not expose
the surface of the polyproplene. (Wet sanding or
dry sanding is acceptable).
13. Wipe the complete surface of the bumper with
degreasing agent. Quickly wipe the surface with a
clean rag to degrease it.
14. Apply a matching coat of paint to the polyproplene
bumper as described in Section 501-32.
Refer to Section 501-32 for refinishing techniques
for other plastic components.
NOTE: The paint for servicing a polypropylene
bumper adheres poorly to a urethane bumper.
Therefore, be sure to use only urethane primer for
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501-25C-4
Body Repairs — Plastic Repairs
501-25C-4
DESCRIPTION AND OPERATION (Continued)
Item
Description
5
Rear bumper side retainer
6
Bumper opening panel
Item
Description
1
Rear bumper arm
2
Rear bumper cover
3
Bumper opening panel
Item
Description
4
Rear lower valance panel
1
Front bumper cover
5
Rear bumper absorber
2
Front bumper absorber
6
Rear bumper side retainer
3
Front bumper retainer
4
Front grille
5
Front lower valance panel
Item
Description
1
Rear bumper retainer
2
Rear bumper absorber
3
Rear bumper arm
4
Rear bumper cover
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