GYS 050932-13-02-2020-V2 Bumper Repair Kit Instructions
- May 15, 2024
- GYS
Table of Contents
GYS 050932-13-02-2020-V2 Bumper Repair Kit
Specifications:
- Model Number: 050932
- Date of Manufacture: 13/02/2020
- Version: V2
Product Usage Instructions
Positioning the Stainless Steel Mesh:
Position the stainless steel mesh onto the break, ensuring that the edges of
the crack are perfectly aligned.
Melting the Mesh into the Plastic:
Use the soldering iron tip specifically designed for this purpose to make the
stainless steel mesh melt into the plastic.
Applying the Brazing Stick:
Apply the brazing stick with the melted side against the part to be repaired.
Operate similar to brazing with tin.
Cooling and Finishing:
Leave the surface to cool down and then sand off the excess material using
sandpaper (grain 40 or 80). For finishing sanding,use ABRALON abrasive for a
perfect surface. Clean, blow, and apply plastic primer.
Additional Repairs:
If needed, use a specific plastic mastic to address aspect defaults or lack of
material. For plastics like car body elements,where the steel mesh cannot melt
deep into the plastic, follow the JBDC brazing sticks process after sanding
and cleaning.
Final Touches:
Cover entirely the area to be repaired with brazing material.
Apply the steel mesh on the brazed area and insert it in the melted material
deposited; then charge again with brazing material.
Safety Instructions:
BEWARE: Never leave the soldering iron switched on with the tip facing
down, as the body of the soldering iron may overheat and deteriorate. In case
of bad air extraction, wear a breathing mask.
Frequently Asked Questions (FAQ):
Q: Can this product be used on all types of plastic materials?
A: This product is suitable for repairing various plastic materials;
however, some plastics may not allow for deep melting of the steel mesh.
Q: How should I clean the repaired area before applying the plastic
primer?
A: Ensure that the surface is thoroughly sanded, free of excess material,
and any grease is removed before applying the plastic primer for optimal
adhesion.
Check the type of plastic to be repaired
The easiest way to identify the type of plastic you are working on is to look
at the ID symbol on the backside of the part. Ex : PP/EPDM – PE – PP – …
There are 2 types of plastics Bumpers
- Thermoplastic
- Thermoset
Thermoplastics symbols are: PP-PE-PP/EPDM -TEEE-TPE-TPO-TPU-TPUR Thermoset
symbols are : PUR-RIM-RRIM-EEBC
Thermoplastic or Thermoset bumpers should be repaired in a different way.
The Car Manufacturers indicate the nature of the plastics on the parts.
The concept of brazing repair consists in melting a stainless steel mesh
inside the plastic, using an electric soldering iron with a specially designed
tip, and a fine stainless steel mesh 18/8 (ref. 052949 – Stainless Steel mesh
25cm x 12.5cm).
This mesh will actually reinforce the repair, and ensure the solidity and the
flexibility of the bumper. The finishing and the filling of the holes or
breaks will be done by adding the recommended plastics brazing material (ref.
052956 – Plastic Brazing Sticks), which is Polypropylene reinforced with glass
fibre and carbon fibre. This filling material is applied just like a tin
soldering.
Operating instructions
Connect the soldering iron to a 230V electrical supply. The soldering iron will gradually heat up to its working temperature.
Instructions of Use
It order to optimize the quality of the work, it is recommended to work on elements dismantled from the car. Indeed, in case of a break or a crack in the bumper, a back reinforcement is recommended to make the repair stronger. However, a hole in the front of the bumper can be repaired without taking off the bumper. To do so, 1/2mm of material should be grinded around the hole in order to avoid higher thickness around the hole; grind 3 to 4 cm around the hole, bevelling the edges, and melt the stainless steel mesh in the plastic. Once this operation is finished, fill with the brazing sticks (filler ref. 052956).
Preparation of the surface of the bumper :
Clean and remove any grease on the part. Do not use cleaning products with
solvents. Soapy water will be preferred to any other cleaning product. Cut a
piece of mesh, in order to cover the whole of the break or crack, and extend
3cm on either side of the repair to be performed. The stainless steel mesh
will come on the back of the bumper and will act as reinforcement.
Grind the area to be repaired using abrasive paper with grain 40. Avoid a too
fast rotation speed, which would make the plastic material melt. A slight
grinding is enough, in order to remove the paint or any other covering
product.
Position the stainless steel mesh onto the break, taking care that the edges
of the crack are perfectly aligned. Make the stainless steel mesh melt into
the plastic, using the soldering iron tip specifically designed for this
purpose (photo 1).
Do not press too hard on the soldering iron. The temperature of 550°C of the
tip is quite sufficient to make the melted plastic go back up through the
stainless steel mesh. Once this operation has been performed, and for a very
limited cost, your bumper already has quite a good resistance to stress and
shocks (photo 2).
Never use another mesh than the one provided by JBDC. Indeed, in order to save money, you may be tempted to use a fine steel mesh, or even an aluminium mesh which is commonly found on the market.
- the steel mesh, when being heated will oxidize quickly and the risk is to have traces of oxidation coming back up under the paint; furthermore, the mesh will degrade with time, fragilizing the repair that you have just performed.
- the aluminium mesh has no particular mechanical resistance, and it will tear off under stress.
Once this operation is finished, leave the mesh to cool down (you can use compressed air to cool faster). In the front of the bumper, grind largely around the break. Chamfer the edges of the break. You can chamfer using the extremity of the soldering tip, on the sharp side, by melting the plastic. Blow off, clean and remove grease (soapy water is enough, rinse); take off the dust.
Fill the chamfer with the JBDC brazing sticks ref. 052956.
Pre-heat the brazing stick (photo 3) until it is melted on half of the
thickness (this recommendation is important, as it allows a good match by
capillarity with the bumper).
Apply the brazing stick, melted side against the part to be repaired.
Operate jus like brazing with tin (photo 4).
Leave the surface to cool down and blow.
Sanding: take off the excess material using sanding paper grain 40 or 80. For finishing sanding, in order to obtain a perfect surface, it is recommended to use ABRALON abrasive. Once the finishing sanding is performed, clean, blow, and apply plastic primer.
In order to remove aspect defaults or lack of material, a specific plastic mastic can be used.
Comment: some plastics like the car body elements can be repaired with
the brazing sticks process, but it will not be possible to make the steel mesh
melt deep into the plastic.
In this case, after perfectly sanding and removing grease on the edge of the
break, braze with the JBDC brazing sticks.
Cover entirely the area to be repaired.
Apply the steel mesh on the brazed area and insert it in the melted material
deposited; then charge again with brazing material.
Information :
- SMC – Glass fiber – UP – FRP do not solder together. They should be glued (Use UV PATCH and FASTSEALER)
- ABS – PA – PC/PBT – PPO do not seal with brazing process, but can be glued.
BEWARE: NEVER LEAVE THE SOLDERING IRON SWITCHED ON WITH THE TIP FACING DOWN, AS THE BODY OF THE SOLDERING IRON MAY OVERHEAT AND DETERIORATE. IN CASE OF BAD AIR EXTRACTION, WEAR A BREATHING MASK.
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