Identifying the Plastic The easiest way to identify the type of plastic you're working with is to look for

the Plastic ID symbol the backside of the part. Simply match the symbol on the part with the table below and look at the suggested repair method. See the next page for tips when you can't find the Plastic ID symbol. PETE PP - polypropylene

HDPE - high density polyethylene

PS - polystyrene

PVC - polyvinyl chloride

Resins not mentioned above, or a combonation of plastics.

LDPE - low density polyethylene

Symbol & Type PUR, RIM, RRIM Thermoset polyurethane SMC, UP, FRP

Suggested Repair How to identify Typical Usage Method Usually flexible, maybe Flexible bumper covers Method A w/ urethane yellow or gray,bubbles (esp. on domestics), filler rod or Method C w/ Uniand smokes when panels, rocker panel covers, Weld FiberFlex attempting to melt. snowmobile cowls. Rigid, polyester matrix Rigid body panels, Method E - two-part

Repair Tips Don't try to melt the base material! Just melt the rod into the v-groove like a hot melt glue. Use backing plate over holes,

Fiberglass

reinforced with glass fibers, sands finely

fenders, hoods, deck lids, epoxy repair header panels, spoilers withfiberglass reinforcement. Method B w/ ABS rod (5003R3), orMethod D Insta-Weld adhesive repair, orMethod E TwoPart epoxy repair Method C w/ Uni-Weld FiberFlex (5003R10)

ABS (Acrylonitrile Rigid, often white but Instrument panels, Butadiene Styrene) may be molded in any grilles, trim moldings, color, sands finely. Very consoles, armrest pungent odor when supports, street bike heated. fairings. EEBC (Ether Ester Flexible, off-white in Rocker cover moldings, Block Copolymer) color, similar in bumper extensions (91-96 appearance to PUR DeVille) (Lomod by GE) EMA (Ethylene Semirigid, molded in a Bumper covers (Dodge Meth- acrylic Acid) variety of colors, Neon 1st generation base unpainted (Bexloy W by model) DuPont) PA Polyamide (Nylon) PC + ABS Pulse (Polycarbonate & ABS) PC + PBT Xenoy (Polycarbonate blend) Semirigid or rigid, sands finely Rigid, sands finely, usually dark in color

layer in fiberglass cloth for extra strength and to approximate thermal expansion Weld repairs may be backed with epoxy for extra strength.

Rigid, sands finely, usually dark in color

PE Polyethylene

Semiflexible, melts &

Method C with Uni-Weld FiberFlex (5003R10) or Method B with slivers cut from scrap. Radiator tanks, headlamp Method B w/ nylon rod bezels, exterior trim (5003R6) finish parts Door skins (Saturn), Method instrument panels, street B w/ Polycarbonate rod bike fairings (5003R7), or Methods D or E adhesive repairs Bumper covers (primarily Method Ford products, 84-95 B w/ polycarbonate rod Taurus, Aerostar, some (5003R7), Method C, Mercedes and Hyundai's) or Method Eadhesive repairs. Overflow tanks, inner Method B w/ polyethylene

Sand entire bumper for refinishing, restore texture with Flex Tex (3800).

Preheat plastic with heat gun before welding, mix rod completely with base material. Preheat plastic with heat gun before welding with Method B. Preheat plastic with heat gun before welding with Method B.

Applying filler or painting is

smears when grinding, fender panels, valences, usually semi-translucent. interior trim panels, RV water storage tanks, gas tanks PP Polypropylene Semiflexible, usually Bumper covers (usually black in color, melts & blended with EPDM), smears when grinding inner fenders, radiator shrouds, interior panels, gas tanks PPO + PA Noryl Semi-rigid, sands finely, Fenders (Saturn & GM), GTX (Nylon blend) usually off-white in exterior trim color. TEEE Flexible or Semiflexible Bumper covers (especially (Thermoplastic (Bexloy V by duPont) on domestics, filler panels, Ether Ester rocker panel covers.) Elastomer) TPE Thermoplastic Semi-flexible, usually Bumper covers, filler Elastomer black or gray, melts & panels, underhood parts. smears when grinding. TPO, EPM, TEO Semiflexible, usually Bumper covers, air dams, Thermoplastic black or gray in color, grilles, interior parts, Olefin melts & smears when instrument panels, grinding snowmobile cowls. TPU, TPU Flexible, sands finely Bumper covers, soft filler Thermoplastic panels, gravel deflectors, Polyurethane rocker panel covers

rod (5003R4) or Method nearly impossible. C w/ FiberFlex (5003R10)

Method C with Uni-Weld FiberFlex (5003R10) or Method B withpolypropylene rod (5003R2) Method B w/ nylon rod (5003R6), orMethods D or E adhesive repairs Method C w/ Uni-Weld Fiberflex (5003R10) or Method B w/ slivers cut from scrap. Method C with Uni-Weld FiberFlex (5003R10)

Use 1060FP Filler Prep adhesion promoter when applying two-part epoxy filler

Preheat plastic with heat gun before welding with Method B.

Use 1060FP Filler Prep adhesion promoter before applying twopart epoxy filler. Method C with Uni-Weld Use 1060FP Filler Prep adhesion FiberFlex promoter when applying two-part (5003R10) or Method epoxy filler B w/ PP or TPO rod. Method B w/ urethane rod (5003R1) orMethod C w/ Uni-Weld FiberFlex (5003R10)

On solubility The following is an incomplete list of the most common plastics used in Nerf and their compatibility with common solvents. A "Y" indicates that the solvent will dissolve the plastic in question. A "N" indicates that the solvent is not recommended for use with that plastic. Either it does not dissolve the plastic at all or does so poorly.

Polymethyl methacrylate (Acrylic) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y - Dichloromethane: Y - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: Y Acrylonitrile butadiene styrene (ABS) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y - Dichloromethane: N - MEK: Y - Methyl benzene: N - Tetrahydrofuran: N Polyacetal (Delrin - POM) - 1,2 Dichloroethane: N - Acetone: N - Cyclohexanone: N - Dichloromethane: N - MEK: Y - Methyl benzene: Y

- Tetrahydrofuran: N Cellulose acetate butyrate (Butyrate) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y - Dichloromethane: Y - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: Y Cross-linked low density polyethylene (PEX) - 1,2 Dichloroethane: Y - Acetone: Y (at 100%) - Cyclohexanone: N - Dichloromethane: Y - MEK: N - Methyl benzene: Y - Tetrahydrofuran: Y Low density polyethylene (LDPE) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y

- Dichloromethane: Y - MEK: Y - Methyl benzene: N - Tetrahydrofuran: N High density polyethylene (HDPE) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: N - Dichloromethane: N - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: N Ultra high molecular weight polyethylene (UHMW) - 1,2 Dichloroethane: N - Acetone: N - Cyclohexanone: N - Dichloromethane: Y - MEK: N - Methyl benzene: Y - Tetrahydrofuran: N Nylon - 1,2 Dichloroethane: N - Acetone: N - Cyclohexanone: N - Dichloromethane: N - MEK: N - Methyl benzene: N

- Tetrahydrofuran: N Polycarbonate - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y - Dichloromethane: Y - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: Y Polyester (Polyethylene terephthalate - PET) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: N - Dichloromethane: Y - MEK: N - Methyl benzene: N - Tetrahydrofuran: Y Copolyester (Polyethylene terephthalate glycol - PETG) - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y - Dichloromethane: Y - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: Y

Polypropylene - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: N - Dichloromethane: Y - MEK: N - Methyl benzene: Y - Tetrahydrofuran: N Polystyrene - 1,2 Dichloroethane: Y - Acetone: Y - Cyclohexanone: Y - Dichloromethane: Y - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: Y Polyvinyl chloride (PVC)* - 1,2 Dichloroethane: Y

- Acetone: Y - Cyclohexanone: Y - Dichloromethane: Y - MEK: Y - Methyl benzene: Y - Tetrahydrofuran: Y *Includes PVC in pipe and flexible tube, as well as CPVC as we use it, since our CPVC is simply Copper-sized PVC and not Chlorinated PVC. Teflon (TFE) - 1,2 Dichloroethane: N - Acetone: N - Cyclohexanone: N - Dichloromethane: N - MEK: N - Methyl benzene: N - Tetrahydrofuran: N

On solvents 1,2 Dichloroethane: Also known as Ethylene dichloride. Found in paint removers. Acetone: Found in small quantities in nail polish remover. Also found in various plastic cements. Also found in acrylic paint thinners and varnishes. Can be bought pure. Cyclohexanone: Found in plastic cement, particularly ABS and PVC pipe cement. Dichloromethane: Also known as Methylene chloride. Found primarily in paint stripper. Used as an industrial solvent. Banned in Europe. Methyl ethyl ketone (MEK): Also known as Butanone. A large component of almost all plastic cements especially ABS and polystyrene cement. Can be bought pure. Methyl benzene: Also known as Toluene. Used mostly as a paint thinner or paint remover. Found along with MEK in polystyrene model kit cement.

Tetrahydrofuran: Found almost exclusively in PVC cement. Can also be in some varnishes.

Plastic cement is generally comprised of a solvent (or mixture of solvents) along with dissolve plastic resin of the plastic in question. Thus PVC cement will contain dissolved PVC along with the solvents. Examples: Genova ABS cement is around 20% Acetone, 60% MEK, and 20% ABS resin. Oatey Green Transition cement is around 40% Tetrahydrofuran, 35% Acetone and MEK, 10% Cyclohexanone, and 15% PVC resin. Look either on the can or search for Material Safety Data Sheets for the ingredients and quantities, and then look up which plastics these will work with.

PLASTICS RECOGNITION So that you can recognize which plastic you are dealing with, the following simple test is recommended: 1. A short test weld with the available welding rod. If the welding rod or tape is fixed firmly, the problem is solved. 2. Take a small sliver or shaving of the material to be welded and light it with a match, observe the flame and smell the smoke. On PVC blackish smoke and acrid smell On Polyethylene no smoke, the material drips like a candle and also smells of wax On Polypropylene no smoke, the material drips like a candle and smells of burnt oil On Polyamide no smoke, pulls to form thread, smells of burn horn On Polycarbonate yellowish sooty smoke. Sweetish smell On ABS blackish smoke, soot flakes, sweetish smell The welding rod and tape has the following colors: Welding temperature in C Hard PVC rod grey and red 300C Soft PVC rod transparent 400-500C Soft PVC tape grey 400-500C Hard Polyethylene rod black and white 300C Hard Polyethylene tape white 300C Soft polyethylene rod black 270C Soft Polyethylene tape transparent 270C

Polypropylene rod grey 300C Polypropylene tape natural 300C Polymide rod black 400C Polycarbonate rod transparent 350C Xenoy tape grey 350C ABS rod white 350C ABS tape white 350C Because containers, pipes and foils are available in many different colors, it is not possible to judge from the color of an Article from which thermoplastic it is made. Since however 50% of goods are made of types of polyethylene this eases your recognition problem. If contrary to expectations you have problems when welding, contact the service center at the address

1999-2000 2005-2009

GMC Truck GMC Truck

Jimmy/Yukon (full Size) Denali S15Jimmy/Envoy w/denali model

Rear Front

TPO or TEO (Thermo Plastic Olefin) TPO or TEO (Thermo Plastic Olefin

Sand backside of area to be repaired with 50 grit paper or coarser. Heavy grooving of the plastic is desirable to maximize the mechanical strength of the bond. Afterward, sand lightly with 80 grit for finer grooving which will further improve adhesion. If the material is TEO, TPO or PP, you must apply 1060FP Filler Prep Adhesion Promoter. Brush onto the sanded area and allow to flash off. Apply Fiberglass Reinforcing Tape over the damaged area. If part is SMC, cut a backing panel from a scrap piece of SMC. Make sure the backing panel extends at least 2" beyond damage in all directions. Choose a two-part epoxy adhesive system to match the hardness of the substrate.

Repairing Plastics with Two-Part Epoxies

Flexible 2000 Flex Filler 2 (gray) Rigid 2020 SMC Hardset Adhesive Filler (gray)

Mix epoxy adhesive in equal parts, apply over fiberglass reinforcing tape on backside of repair. Allow 15 minutes to cure before handling. On SMC, apply a bead of 2020 SMC Hardset Filler to the backing panel and press into place. Allow epoxy at least 20 minutes to cure before handling. Sand frontside of damaged area with 50 grit paper or coarser and v-groove away from tear. The deeper and wider the v-groove is, the stronger the repair will be. Remove paint in the surrounding area and radius into the v-groove with 80 grit in a DA. Again, if the material is a TPO or PP, apply 1060FP Filler Prep Adhesion Promoter. Mix and apply selected epoxy adhesive. Build up slightly higher than the surface to allow for sanding. Allow at least 20 minutes to cure before sanding. On SMC, layer pieces of 2043-U Uni-Cloth fiberglass cloth into the v-groove between coats of epoxy. Use a saturation roller if necessary to fully wet the cloth with epoxy. Contour and smooth the surface with 80 and 180 grit paper.

Repairing Plastics with PlastiFix Rigid Plastic Repair Kit

The PlastiFix Rigid Plastic Repair Kit is a revolutionary plastic repair system that allows you to repair cracks, fill gaps, rebuild tabs, and fix stripped threads. The most unique feature of the PlastiFix Rigid Plastic Repair Kit is the FlexMold flexible molding bar. The FlexMold bar allows you to replace a broken tab by forming a mold from an undamaged piece, then casting your new part using the PlastiFix acrylic adhesive system. This system does not work on olefinic plastics like PE, PP, TEO, or TPO.

Getting Ready

Dispense powder into cup

Use pipete to dispense liquid into the dropper bottle.

Insert dropper tip into bottle and place applicator needle onto dropper tip.

Application

Squeeze one drop of liquid into powder.

Pick up liquid/powder mix with tip of needle.

Squeeze bottle to apply liquid/powder mix to repair area.

FlexMold Molding Bar Use

Place FlexMold bar in very hot water until softens. Shape FlexMold bar over pattern. Caution! Very Hot!

When FlexMold bar cools position in repair area

Fill mold with PlastiFix powder/liquid mix, allow to cure, remove mold

Reinforcing

Cut fiberglass cloth to cover damage on backside. Cover fiberglass cloth with thin layer to PlastiFix powder.

Saturate powder with PlastFix liquid.

Cover with plastic sheet, press to shape, allow to cure.

Repairing a crack with PlastiFix

Sand away the paint surrounding the crack V-groove along the crack line using a Dremel tools

Smooth out sharp Apply aluminum tape angles with sandpaper to the backside to prevent PlastiFix from flowing out.

Repairing Stripped Threads

Drill or file threads from hole.

Apply lubricant to screw threads

Apply PlastFix powder/liquid mixture to screw threads. While adhesive is wet, insert into hole.