Nitrogen Plastic Welding: Hyundai Sonata Tab Flange Repair

Some bumper covers, particularly 2011-2013 Hyundai Sonatas, are known to have tab flanges that break off from the bumper cover. These bumpers have a groove along the edge where the plastic is paper-thin. This is a common design on bumpers today, so this technique can be used on any bumper of similar design.

Always wear proper safety gear while working!

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Products Used:

Note: This is a list of the Polyvance products that can be used to make this repair. This list does not include sanders, grinders, or other common tools you will need. If you have any questions, please don't hesitate to call technical support at 800-633-3047.

• 1000 Super Prep Plastic Cleaner (several options available) OR 1001-4 EcoPrep Plastic Cleaner
• Stainless Steel Reinforcing Mesh (several options available)
• Aluminum Body Tape (several options available)
• Nitrogen Plastic Welder (several options available)
• Polypropylene welding rods
  Note: We used polypropylene here because of the identification symbol. Choose the rod that matches the plastic you need for your repair.

Video Notes:

• English Closed Captions have been provided for this video. Click on the CC button to turn them on or off.
• The length of this video is in no way representative of the actual time required to perform a complete repair and therefore should not be used for estimating purposes.

English Transcript:

The length of this video is in no way indicative of the amount of time it takes to perform this procedure. It should therefore not be used for estimating purposes.

Some bumper covers, particularly 2011 through 2013 Hyundai Sonatas, are known to have tab flanges that break off from the bumper cover. These bumpers have a groove along the edge where the plastic is paper thin. This is a common design on bumpers today, so this technique can be used on any bumper of similar design.

As with any quality repair, begin by cleaning the work area. Use 1000 Super Prep or 1001 EcoPrep plastic cleaner. Using 80 grit sandpaper, scuff the area you'll be welding on both the flange and the bumper. Neatly fit the flange to the bumper and tack weld using an airless plastic welder to hold it in place. Alignment of the flange is critical for proper panel gap. Make sure the alignment is perfect before you begin tack welding. Reinforce the tab using small strips of 2045W Stainless Steel Reinforcing Mesh.

Apply aluminum tape to the topside of the flange using a body spreader to smooth and fit inside the groove. This will prevent plastic from melting through during the weld, as well as provide additional reinforcement. On the underside, weld a pass of plastic using R02-08 angled welding rod. Be sure to move the torch back and forth to heat the entire surface area of the rod, as well as the base. The key to a strong nitrogen weld is to melt both the rod and the base at the same time. Once you've finished, reheat the weld with nitrogen a few inches at a time, then smooth using an airless plastic welder. The weld must be flush in order to fit properly with the mounting bracket.

Use R02-01 eighth-inch diameter welding rod to repair any tight corners that may have been missed by the angled rod. Allow to cool and remove the aluminum tape. Use a razor knife to remove any excess plastic. Because this repair will not be seen, no finish work will be necessary.

As you can tell by this strength test, this simple procedure repairs the tab beyond that of OEM quality using tools and supplies from Polyvance.

Look to Polyvance for all of your plastic repair product and training needs. We offer I-CAR Industry Training Alliance courses as well as other hands-on classes, in addition to the video resources you can find on our website and on our YouTube channel.