Mazda 5. Manual — part 82
09–80E–4
BODY STRUCTURE [PLASTIC BODY PARTS]
serious to be restored by painting only.
1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make
an angle of about 45
°.
2. Weld the damaged area.
• For repair of a cracked area, melt the crack together with a heat gun and a melting attachment.
Hole
A
A
A-A Section
Crack
B
B
C
C
Flaw
D
D
B-B,
C-C
Section
D-D Section
Top coat layer
Primer layer
Primer surface layer
Polypropylene layer
4
4
3
3
1
1
2
2
ZUA9818B001
A-A, B-B, C-C Section
Cut with knife
Polypropylene surface
D-D Section
Cut with knife
Sand
Sand
Angle necessary for deposit of polypropylene welding rog
45
°
ZUA9818B010
BODY STRUCTURE [PLASTIC BODY PARTS]
09–80E–5
09
• For repair of a hole, degrease the area on both sides of the bumper and apply aluminium tape on the
reverse side of the damage area.
3. Melt the polypropylene welding rod with a heat gun and deposit it the cracked area.
Note
• Heat the shaded area to melt it.
• Take care not to overly melt welding rod. If the part is welded with the welding rod melted like jelly, the
welding strength will be reduced.
• Hold the heat gun 10—20 mm {0.39—0.79 in} from the part being welded.
• Do not move the welding rod until the welded parts cool.
Polypropylene surface
Heat gun
Attachment for
melting
painted surface
Melt together
B-B,C-C Section
Section after melting
ZUA9818B003
A-A Section
Degrease
Aluminium tape
ZUA9818B005
Polypropylene welding rod
Polypropylene welding rod
Melt this area
Melted area
B-B,C-C,D-D Section
ZUA9818B004
Polypropylene welding rod
Polypropylene welding
Paint
Top view
A-A Section
Surface
Aluminium tape
ZUA9818B006
09–80E–6
BODY STRUCTURE [PLASTIC BODY PARTS]
4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to
which repair agent will be applied.
5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about
10 minutes at 20
°C {68 °F}.
6. Mix the main agent and the stiffening agent in a ratio of one to one. Apply the mixed repair agent to the
damaged area.
Note
• When mixing the main and stiffening agents, take care not to allow bubbles to form.
• The repair agent hardens quickly (about 5 minutes); proceed with the work immediately after mixing the
agents.
• Allow about 30 minutes to dry (20 °C {68 °F}) before sanding.
The repair agent is a two part epoxy adhesive.
When the repair agent hardens, it will provide a good finish with the same flexibility as the polypropylens.
The repair agent for a urethane bumper is also a two part adhesive compound. However, this is different from
that for a polypropylene bumper. If the incorrect repair agent is used, the repair will be faulty.
7. Sand the area with #180—240 sandpaper.
Note
• If excessive force is applied to the area when sanding, the surface will be damaged.
• If fuzz remains around the repaired area, melt it with a heat gun.
Sand gradually
Sand repair area
Paint
YMU980PCX
Larger than repaired area
Polypropylene primer
YMU980PCY
Repair agent
Do not mix air
Weld
Polypropylene surface
YMU980PCZ
BODY STRUCTURE [PLASTIC BODY PARTS]
09–80E–7
09
8. Degrease the painted surface.
9. Mix the primer and the hardener at a ratio of one to one. Apply the primer to the repaired area and the surface
of the bumper with a brush or spray.
Use the primer within 16 hours after it is mixed.
Note
• Polypropylene primer will dissolve even after drying if it is wiped with solvent. Use only water to clean
around the primer.
10. Allow the part to dry.
11. Add the softener to the urethane primer surfacer and spray it on the repaired area.
a. Mixing method
Urethane primer surfacer + Softener . . Mixture A
Mixture A + hardener . . Mixture B
Dilute mixture B with thinner to spray on bumper
b. Viscosity
YMU980PD0
1
1
polypropylene primer
Primer hardener
YMU980PD1
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