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Another new tool needed...Really!

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

scot850
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Volvo Repair Database Another new tool needed...Really!

Post by scot850 » Thu Jun 01, 2017 11:30 pm

So the endless new saga of the 2000 V70 NA/base continues. Hopefully the majority of the mechanical and interior repair work has been completed. Still some stuff to do, but the last major issue I wanted to tackle prior to returning the car to the road for shakedown runs (to see what else falls off!) was to try to repair some of the damage the PO had inflicted on the poor cars front bumper. It appears the PO parked by touch in every parking bay she went into. The bottom of the bumper is totally scratched with deep scratches, and also a couple of 'dog-ear' tears in the bottom lip from presumably driving it over a stop block in a parking bay and then backing off over it and catching the bumper.

I had removed the bumper to fix the head-light wiper motor and in fact the whole washer system too which included the washer bottle too. As I hate doing body work due to lack of patience, I had thought I'd farm this out to pros, but due to a huge over-run I can't afford to do that, although, I found that the coast of buying all the materials required to repair an ABS plastic bumper is also high. Anyway, the first task was to rub down the area around the cracks and I then planed to use special plastic 2 part glue to repair the cracks. I had even bought the double syringe dispenser and the 2 part glue and some web to spread over the crack for strength. But a chance reading of a Princess Auto sale catalogue, showed an new item on sale, which was a plastic welding kit for $55 CDN. That was cheaper than the double dispenser unit for the glue pack! So I returned the glue pack and dispenser and bought the welder instead.

Basically it is a modified gas soldering iron with a few mods:
2000 V70 base bumper repairs 012.JPG
The kit includes 4 sets of different plastic strips, 2 welding tips of different sized, a brass cleaning brush, a small round file, 4 types of plastic welding strips and some fine mesh metal gauze for repairs with larger holes.

I prepped the cracks by drilling a hole at the end of the cracks to prevent crack propagation, then used a dremel with a small conical grinding stone to grind a 'V' notch on either side of the cracks in the bumper (i.e. front and back).

Then I picked the ABS plastic welding sticks and remove one for use. There is a hole through the welding tip that you pass the plastic welding rod through. It has the plastic rod coming though parallel wit the tip surface. With the tip up to temp., I practiced melting the bumps around the cracks to flatten them first, and then ran a bead of plastic weld down both sides of the crack. Is it pretty, no. Does it work, yes, and with a bit of practice it got easier. I have rubbed the front of the bumper repair down with sandpaper and they are now ready I reckon for filler to hide the front of the repairs.
2000 V70 base bumper repairs 001.JPG
The crack runs vertically down from the top of the picture for about 2" in length. I also had to add more plastic (which has to be rubbed down) to replace plastic in a bad gouge nearer the bottom lip (top of picture) which was also sitting lower than the rest.
2000 V70 base bumper repairs 002.JPG
Tomorrow or when time next allows I will tackle the special plastic filler all along the bottom edge of the bumper as the gouges are too deep to repair by rubbing down alone.

This poor bumper and other areas of the car ( rear tailgate spoiler and rear bumper) also took abuse.
2000 V70 base bumper repairs 003.JPG
2000 V70 base bumper repairs 004.JPG
2000 V70 base bumper repairs 005.JPG
2000 V70 base bumper repairs 006.JPG
2000 V70 base bumper repairs 008.JPG
2000 V70 base bumper repairs 009.JPG
2000 V70 base bumper repairs 010.JPG
2000 V70 base bumper repairs 011.JPG
I don't plan to repair the rear bumper and tailgate spoiler just yet, but they are on the plan once the car has been run for a while, along with a buff and polish. But that will be later.

Was the plastic welder worth it? I reckon so, and the fact you don't have glue that will go off and costs $40/pack it seems a bargain. I think with more practice it can do a pretty good job for the price, but for me in this case it is good value for money.

Neil.
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2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

DeathRex
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DeathRex

Re: Another new tool needed...Really!

Post by DeathRex » Fri Jun 02, 2017 10:02 am

You can cement ABS together with acetone. With patience, you can buff ABS with acetone to remove blemishes. You can even get ABS to shine or dull with acetone. I use it a lot at work, never have tried it on a Volvo though.



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dyn blin
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dyn blin

Re: Another new tool needed...Really!

Post by dyn blin » Fri Jun 02, 2017 10:44 am

Thanks for that Neil,

I've been hesitating on purchasing the 3M solutions that include the expensive double barrel dispenser, epoxy and re-enforcing backing.

This seems like a potentially more cost-effective solution if your experience shows the repairs holding up.


'97 850 GLT Wagon- Driving to see 300k in the rearview

scot850
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scot850

Re: Another new tool needed...Really!

Post by scot850 » Fri Jun 02, 2017 11:25 am

So far it is obviously very early days after the repair. But realistically, there is no real reason you should have a problem post repair. I have considered using some of the steel mesh on the rear lower edge of the crack to reduce the likelihood of it splitting again if 'someone' hits a kerb edge again with it. I did try bending the repair area it see what happened, but it has stayed fairly flexible. As the plastic was melted on the bumper as well as the new plastic, I can see no reason for it to re-break easily.

My process included cleaning the area first using wax/surface cleaner, then rubbed it down to key the area around it, but I think the last part is overkill as you will melt the plastic around the damage with the heat anyways. I then 'V' notched the split both sides of the bumper (I.e. front and back) and only then added the plastic. It is definitely easier to do whilst working from above the repair (horizontal) or the repair is vertical. Trying to repair it from underneath was a was of time as the plastic tended to fall off before it bonded. I made the mistake of trying to repair the rear from below, and was able to do it, but it will not win any beauty contest any time soon! However, I did make the repair at the back a little thicker for added strength.

The other point I'd make is you are actually working the area around the crack too so you do spread the repair 'load' over a larger area than just the crack. Do remember to drill a hole at the end of the crack prior to repair to prevent any future spreading of the crack.

I did have to use my heat gun before starting the repair as the plastic around the cracks had been bent and this allowed me to mold it back flat so the sided of the crack met.

If anything else changes I'll let you all know. But I do not see why this is likely to be any worse a repair method than the glue type as the glue relies on the adhesion to the plastic surface, rather than being melted into it.

I can see that the glue method may be needed for bigger holes as it may be easier to work it to fill more easily.

The biggest pain is that there have been a few Nautic Blue (code 417) P80 V70/S70's through the PnP's recently, but of the 4, 2 were V70XC's (different front and rear bumpers, rear with the cut out on the wrong side for the muffler) and the 2 V/S 70's had been stuffed at the front or the bumpers were equally nasty. The advantage would have been the whole cover is about $50 if you can find a good one.

Neil.


2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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wizechatmgr
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wizechatmgr

Re: Another new tool needed...Really!

Post by wizechatmgr » Fri Jun 02, 2017 9:47 pm

See if you can set your heat between 230-250c that should work fine for most ABS.


Wisdom requires knowledge as a prerequisite, but knowledge can be developed due to a lack of wisdom.
In order to learn how to fix something, you must first learn how to break it.
1999 V70 XC AWD - ~183k miles

scot850
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scot850

Re: Another new tool needed...Really!

Post by scot850 » Fri Jun 02, 2017 10:52 pm

The unit does have an adjustable slide for temp control. Only issue is I done' have anything to hand to measure the temp of the unit. I worked on the basis of it melted enough of the original material without holing all the way through, whilst heating the supplied stick of ABS sufficiently to allow me to mold it into the crack.

My apologies to Death Rex on not commenting on the use of Acetone for melting ABS plastic. That may work ok on some applications, but in this case, the plastic was missing material and needed more to be added back in for strength on the repair. If I had just used acetone I would have had to 'melt' the bumper material sufficiently to 'stretch' the material around the crack that it make the material extremely thin and therefore brittle. But it is a good point to make a note of for the future.

Thanks guys.

Neil.


2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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Winnebago
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Winnebago

Re: Another new tool needed...Really!

Post by Winnebago » Wed Jun 21, 2017 11:08 am

re: plastic welding - i had been looking at doing plastic welding for the center console. you know... the piece that breaks off when you flip the cupholder up a bit too enthusiastically... found some youtube videos with people using soldering irons. and another technique with crazy glue + baking soda. I figure I would try those methods first as I do not have big gaps to fill.

re: temperature - buy an infrared thermometer from amazon. will run you between $12 to $17. very useful. I use it on home heating/ac vents and my komado smoker... tried measuring fever temp a few times too. :) https://www.amazon.com/s/ref=nb_sb_noss ... hermometer


'98 V70 T5M - lots of R parts - 201k+miles
'98 S70 GLT - bought new. sold at 185k miles

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volvolugnut
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Re: Another new tool needed...Really!

Post by volvolugnut » Fri Nov 29, 2019 5:34 pm

scot850,
How is the plastic weld repair holding up? It has been a couple years. How is the rest of the project progressing?

volvolugnut


2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

scot850
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scot850

Re: Another new tool needed...Really!

Post by scot850 » Sat Nov 30, 2019 12:15 am

Car has moved onto a good Volvo loving friend. Bumper is still holding up to our large temperature variations here. New owner just loves the car and won't let other family members (including his wife!) drive it.

Neil.


2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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Re: Another new tool needed...Really!

Post by abscate » Sat Nov 30, 2019 4:53 am

Nautic Blue Volvo people are special.


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