Tab Repairs: Three Easy Methods

The most often damaged part in a collision is the front bumper cover, followed closely by the rear bumper cover. Many bumper covers are discarded simply because the tabs and mounting holes are broken. However, these can be repaired, and we have three methods for repairing them. The decision for which method to use depends on (A) the type of plastic and (B) the severity of the damage.

	Method 1 Weld	Method 2 Uni-Weld	Method 3 Insta-Weld
Type of Plastic	Can be identified	Thermoplastics	Can or Cannot be identified
Severity of damage	Minor to major damage	Minor to major damage	Small tears only
Advantages	Works best with urethane	Works best with TPO and polypropylene.	Quick repair for small tears.
Disadvantages	Identifying plastic	Not as strong as a true weld	Limited flexibility

Method 1 - the standard weld method, you actually create a new tab with melted plastic. This method requires that you identify the plastic. This method makes very strong repairs on urethane bumpers. We have found that the Uni-Weld repair method is more effective with TPO and polypropylene.

Method 2 - the Uni-Weld method, works on thermoplastics, and especially well on problem plastics like TPO and polypropylene. Those of you who have attempted to use Method 1 on polypropylene may have had difficulty getting the rod to fuse with the base material. If this sounds familiar, you should have success with the Uni-Weld method.

Method 3 - the Insta-Weld method, is very quick but only recommended when the tab has a small tear, not when the tab is completely torn off. It is important to use Insta-Weld 3, because it is rubber toughened and has some flexibility. Be sure to use Bond-Prep when working with TPO and polypropylene. (See article on Insta-Weld 3.)

Method 1 - Weld Repair

Step 1

Clean part thoroughly on both sides with soap & water and 1000 Super Clean plastic cleaner. Bevel and grind what is left of the tab. Apply aluminum body tape to bottom to make a mold for the new tab. Bevel inside the hole too, and remove paint in the area.

Step 2

Melt the appropriate rod into the "mold" and into the base material. You are actually making a new tab. Remove the aluminum tape and finish filling in the backside. Note: On urethane, do not attempt to melt the rod into the base material, just melt the rod onto the base material.

Step 3

Congratulations. You have just created a new tab. Don't try to do this with two-part epoxy systems.

Step 4

Grind away excess weld material and redrill the hole if necessary.