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Old 08-29-2015, 07:08 PM   #1 (permalink)
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Default Plastic Bumper Repair

What's up guys, got another DIY on some repair work at my job.

I know a lot of you guys might be picking up used bumpers, which usually have some dents, scrapes, scratches, and all sorts of damage. It's much harder to find a clean one nowadays, but I'm a fan of used OEM parts for their fitment and materials.

This bumper was hit right where the bumper splits in two (it's a two piece bumper) and had gouges in it as well as a pretty sizable dent.

Here's a gouge on the bottom portion



And a couple pictures of the dent and scrapes on the upper portion





First thing's first, let's get that dent out.



I used a heat gun on the back of the bumper right where the damage was. The trick is to heat it up to the point where the bumper becomes very flexible, but not too hot or the plastic starts to melt. You'll see this as the plastic gets darker and shinier when it's too hot.

I didn't get a picture of this because it's pretty self explanatory, but what I did was take the back side of a screwdriver (preferably plastic) and I worked the dent out until the dent was pretty much gone.

This is once I got the dent worked out. It might take a couple heating processes and massaging of the plastic



Once you get the dent out, let that cool down for the next step.

I usually start out sanding a bumper with 180 grit on my DA



Keep the DA nice and flat, don't use the edge or you can actually do worse damage to the bumper and your repair won't be as straight.

This is during sanding, notice the scrapes starting to disappear as I level the plastic.

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Old 08-29-2015, 07:39 PM   #2 (permalink)
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Here's the plastic once I got it nice and smooth with no scrapes left



Now sometimes I like to use a product called EZ-Sand. It's a flexible plastic filler that sands kinda like filler. Since this was at work, I like to make things perfect and the plastic wasn't quite where I wanted it.

First, spray the bumper with a light quick coat of adhesion promoter to help the EZ-Sand stick



Here's the EZ-Sand. It's a two part tube and needs a dual plunger gun to dispense it



It spreads a little harder than a filler, but it levels out real smooth. Here's a couple pictures of once it's applied





Once that's dried, you can block this stuff out with a sanding block and 180 grit. Like I said, it sands really well and it blocks out just like filler on a dent on sheet metal.

After all your filler is blocked to perfection, I take a block with 320 to sand out the 180 scratches. Once you're done sanding, it should look like this



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Old 08-29-2015, 07:40 PM   #3 (permalink)
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And now you're ready for primer and paint! I got a couple of pictures of this bumper before I put it back on the car so you can see what the repair looks like





And that's it! Let me know if you have any questions
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Old 08-29-2015, 08:53 PM   #4 (permalink)
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Great post man!!! I am hoping I can repair my rear bumper. I do believe my front bumper is screwed
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Old 08-29-2015, 09:32 PM   #5 (permalink)
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Good how to, may have to use this on a few spots on my front bumper cover. OEM CRX parts are tough to find around here.
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Old 08-30-2015, 06:24 AM   #6 (permalink)
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Thats exactly what I need!!! Thank you!!!
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Old 08-30-2015, 07:02 AM   #7 (permalink)
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Man great work and write up, thanx
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Old 08-30-2015, 08:19 AM   #8 (permalink)
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YEaa.. how much is the dual plunger for that 3M stuff.


If I had body shop connections,those plungers are all over the place. But for the backyard DIY'er spending that much for a plunger and the 3M e-z sand (let alone trying to find it) seems out of reach.

Im mean, great DIY IF you have the DA sander and all the pro tools to do the job right.
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Old 08-30-2015, 08:21 AM   #9 (permalink)
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I think it is interesting to see how pros do vs us, some times it is out of reach but other times it gives me ideas on how to approach a body shop or the work my self.

Plus it is fun to watch any one with a skill fix something that some one else cannot.

Lots of win in this one. Nice DIY for sure.
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Old 08-30-2015, 05:14 PM   #10 (permalink)
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Quote:
Originally Posted by Esotericimage View Post
YEaa.. how much is the dual plunger for that 3M stuff.


If I had body shop connections,those plungers are all over the place. But for the backyard DIY'er spending that much for a plunger and the 3M e-z sand (let alone trying to find it) seems out of reach.

Im mean, great DIY IF you have the DA sander and all the pro tools to do the job right.
Yeah I know the EZ sand is kind of expensive and all. You dont have to use it, if you work the bumper out good enough, 180 grit should be able to level the plastic near perfect. I fix a ton of bumpers with no ez sand and they come out great!
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Old 08-30-2015, 05:30 PM   #11 (permalink)
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Nice!

Now come fix my quarter panels lol
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Old 08-30-2015, 06:37 PM   #12 (permalink)
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Nice!

Now come fix my quarter panels lol
I would if you could come here! Delaware is kinda far though haha
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Old 08-31-2015, 07:16 AM   #13 (permalink)
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Thanks Samuel! This is exactly what I need for my Wagon and CRX.
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Old 08-31-2015, 07:17 AM   #14 (permalink)
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If not EZ sand then what else do you suggest?
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Old 08-31-2015, 08:29 AM   #15 (permalink)
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If you need something to fill with, but don't have ez sand, I'd say just a super thin coat of regular finishing glaze works. Modern ones are pretty flexible, and older Honda bumpers aren't as flimsy as new ones so you should be good.

Glad I could help LowFlyin'!
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