1993 Ford Mustang Cobra Bumper Repair

We recently repaired a 1993 Ford Mustang Cobra rear bumper for Duke's Body Shop. The bumper was made of polyurethane, and it had some pretty bad damage on it. Polyurethane is a thermoset plastic, and is NOT meltable. It can be repaired with the airless plastic welder and thermoplastic (meltable) polyurethane welding rod. This will not provide a fusion weld; the urethane welding rod is used more like a hot melt glue. We have some photos of the repair process below.

Before:

The 1993 Ford Mustang Cobra rear bumper with damage. Close up of damage on the front side.

Close up of damage on the front side. Close up of damage on the back side.

After Welding:

The 1993 Ford Mustang Cobra rear bumper after welding. Close up of the weld on the front side.

Close up of the weld on the front side.

Close up of the weld on the back side. The 1993 Ford Mustang Cobra rear bumper after welding.

After Filling and Sanding:

Close up of the filled and sanded areas on the front side. Close up of the weld on the back side.

The 1993 Ford Mustang Cobra rear bumper after being filled and sanded.

After Priming:

The 1993 Ford Mustang Cobra rear bumper after being primed.

Finished Product:

Close up of the painted bumper. The 1993 Ford Mustang Cobra rear bumper after being painted its original color.

Bonus Photo! Here's the Ford Mustang Cobra:

A photo shopwing the front and side of the 1993 Ford Mustang Cobra.

More Information:

Want more information about repairing thermoset polyurethane? Watch our videos on thermoset polyurethane repair. Click here for step-by-step instructions and photos.