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