learning to weld plastic
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MotoGP
Joined: Mar 2007
Posts: 3,132
From: Phoenix, AZ
learning to weld plastic
With my purchase of a couple of GSXR front ends (in hopes of fork swap material) the other day I got a pair of cracked up fenders.
So after work today I decided to try my hand at fixing them.
First I stopped by Ace and picked up a 100 pack of black zip ties and a hobby soldering iron. (didn't want to muck up my good one)
Then I grabbed the worse one to learn on and, here are a few before pictures:
Notice one "ear" is completely off, the other is almost gone too, there is a 1.5" hole in one place, and it is cracked almost half way through the middle, in addition to a few small ones here and there.
So now for the after pictures, I still need to see about filing and sanding it, making it pretty etc.. But I ran out of daylight.
Though still ugly, the repairs are strong! it feels as strong as the unbroken one I have.. Assuming I get motivated again this week I will sand it down and throw up final pics.
But I just wanted to share how easy at least the first part of fixing plastic is.
So after work today I decided to try my hand at fixing them.
First I stopped by Ace and picked up a 100 pack of black zip ties and a hobby soldering iron. (didn't want to muck up my good one)
Then I grabbed the worse one to learn on and, here are a few before pictures:
Notice one "ear" is completely off, the other is almost gone too, there is a 1.5" hole in one place, and it is cracked almost half way through the middle, in addition to a few small ones here and there.
So now for the after pictures, I still need to see about filing and sanding it, making it pretty etc.. But I ran out of daylight.
Though still ugly, the repairs are strong! it feels as strong as the unbroken one I have.. Assuming I get motivated again this week I will sand it down and throw up final pics.
But I just wanted to share how easy at least the first part of fixing plastic is.
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Last edited by Malice; May 1, 2011 at 07:29 AM.
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MotoGP
Joined: Mar 2007
Posts: 3,132
From: Phoenix, AZ
Really straight forward, I got the idea off of someone else's repair project here on this forum.
The hardest part is that if you just gob the new material onto cold plastic it will set on top rather than melt with the existing material, just like regular soldering / welding. (called a cold joint in soldering)
On the larger repairs it is easier to premelt a V shaped groove that you fill in with material to make a stronger bond. (again like regular welding where you cut a groove to fill)
Oh and the 25w hobby iron was the perfect temperature, so I wouldn't want a hotter one.. also it came with 5 different tips, and I just used the biggest one.
The hardest part is that if you just gob the new material onto cold plastic it will set on top rather than melt with the existing material, just like regular soldering / welding. (called a cold joint in soldering)
On the larger repairs it is easier to premelt a V shaped groove that you fill in with material to make a stronger bond. (again like regular welding where you cut a groove to fill)
Oh and the 25w hobby iron was the perfect temperature, so I wouldn't want a hotter one.. also it came with 5 different tips, and I just used the biggest one.
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I have a Harbor freight plastic welding tool. It basicly works with hot air. I found it very hard to work with. although I have to admit I didn't work at it very hard.
It might be good for preheating the piece, then apply the "rod" (ziptie) with the soldering iron.
Tom
It might be good for preheating the piece, then apply the "rod" (ziptie) with the soldering iron.
Tom
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SuperSport
Joined: Dec 2008
Posts: 507
From: Arizona
I have no doubt it will hold up. We welded one of the mounting ears back on the other day and I was blown away by being able to hold the entire fender up with the tab and wiggle it around. We took some other very cool pictures of the process as well, he should have them up later.
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MotoGP
Joined: Mar 2007
Posts: 3,132
From: Phoenix, AZ
I thought you were going to post about your handy work, but I will go ahead and post them. 
Here is yruyur showing the crack that he is going to repair on another of the fenders:
Hmm no pictures of his finished work.. Did you not get pics of that? I can take some when I get home. He also welded on one of the small tabs and that turned out great.
Then there was a large chunk missing on that same fender that I filled in:
step one:
Mostly filled in:
Now just needs smoothing and paint:
Here is yruyur showing the crack that he is going to repair on another of the fenders:
Hmm no pictures of his finished work.. Did you not get pics of that? I can take some when I get home. He also welded on one of the small tabs and that turned out great.
Then there was a large chunk missing on that same fender that I filled in:
step one:
Mostly filled in:
Now just needs smoothing and paint:
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