Bumper Grille Bar Repair with the Nitrogen Welding System

Step 1

Look at these broken grille bars to see what I am talking about. This is pretty common on Honda bumper covers, but it happens to others as well.

Step 2

Use a tapered burr on a die grinder to grind a V-groove into the back of the grille bar and in the plastic where the grille bar connects to the bumper cover.

Step 3

Also, grind a "T" in the plastic where the grille bar attatches to the bumper cover.

Step 4

The edge of a Roloc disk may be used to make the groove if you don’t have a tapered burr.

Step 5

Hold the grille bar in place with tape, if necessary, until the repair is complete. This bumper cover is polypropylene so we are using a polypropylene rod with the Nitrogen Welding System. Melt the rod into the groove that you just made and be sure to melt the rod AND the existing plastic together.

Step 6

Weld into the "T" that you created earlier. This strengthens the grille bar considerably. After you melt in all the plastic necessary for the repair, give the rod a twist to break it off. Now, switch the welder from Nitrogen to air to avoid wasting your nitrogen.

Step 7

While the plastic is still hot, use the airless plastic welder to melt in the edges and shape the plastic.

Step 8

Either wait for the plastic to cool or, speed up the cooling with compressed air, like we did here.

Step 9

Some of the plastic may have curled around the grille bar during the repair. Use the airless plastic welder to shape the plastic from the front side.