ATV Plastic Welder

ATV Plastic Welder

The ATV Plastic Welder Kit offers a fast, cost-effective way to repair cracked plastic fenders on ATVs and dirt bikes. Ideal for use on polypropylene and polyethylene, this airless welder delivers durable repairs without the need for special skills or prior experience. This kit allows quick, affordable repairs, eliminating the need for costly replacement parts.

What's Included?

Qty: 1 | Airless plastic welder
Qty: 1 | Bigfoot Welding Tip
Qty: 30 | 12-inch-long plastic welding rods (1/8" diameter round profile)
Qty: 1 | Stainless steel reinforcing mesh (5" x 10")
Qty: 1 | Airless welder stand

Repair Tips

Making the repair stronger: Cut a piece of the included stainless steel wire mesh about an inch wide and the length of your crack (use multiple smaller pieces along the crack if needed). Use the tip of the welder and push it down into the plastic. (It is recommended to do this on the backside because it will not be pretty). Let it cool off and then make your weld. Burying the wire mesh into the plastic is like putting rebar in concrete... it makes it much stronger.

Making the repair look better: You will be able to see where you made the repair. However, you can make it look better. After the weld cools, sand with 80 grit sandpaper and then 180 grit. You can progress to finer grits if you wish. Use a heat gun or a blowtorch over the sanded areas. This will make the sanded area look glossy again. Don't linger the heat too long or you might scorch the part.

Painting/Refinishing: If the fender is polypropylene, you can follow the normal refinishing process. However, polyethylene is virtually impossible to paint.

What's the Difference Between LDPE and HDPE?

The difference between LDPE (low density polyethylene) and HDPE (high density polyethylene) is the length of the molecule chains. HDPE has longer molecular chains than LDPE and the melting temperature of HDPE is often higher than that of LDPE.

LDPE's lower melting temperature usually makes using it as filler rod easier-to-use than welding HDPE filler rod to HDPE plastics.

HDPE is also "tougher" and more abrasion resistant than LDPE, but the practical difference is minimal when doing repair work. If you need the best wear characteristics and can live with making slower, more difficult welds, use HDPE rod. In most cases, we see better quality welds when using LDPE rod for typical crack or hole repair on boat hulls and ATV plastics.

Video - Repairing a Crack in a Dirt Bike Fender

Video - Repairing a Bolt Hole in a Dirt Bike Fender

Product Resources

"The Book of Plastic Repair" is a comprehensive guide to identifying, repairing and refinishing virtually any plastic.