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How to Repair Hard Automotive Plastic Holes

A large portion of automobile components are fabricated from plastics such as ABS. ABS is one of the strongest and most versatile plastics used in the automotive industry. Both collision damage and parts modifications can leave holes in this material that can lead to moisture getting into a cars interior. While small holes are quickly repaired with a few drops of epoxy, larger holes require more work. Use a few simple tools and techniques to repair larger holes, avoiding a costly trip to the auto body shop.

Instructions

1




Clean the area being repaired thoroughly. If the part youre repairing can be removed from the vehicle, remove it and clean both sides of the part. Otherwise, clean the area around and inside of the hole, especially the holes edges. The reason many glues and body fillers fail to work is because a layer of oil or grease forms a barrier between the glue or filler and the part being repaired. This keeps the glue or filler from completely adhering to the part. Liquid dish washing detergent and hot water will work well for cleaning parts, as long as the detergent is formulated to remove grease. After the part is completely dry, apply a 2-inch border of masking tape around the hole.

2

Cut a small disk of ABS, 1/4 inch larger than the hole. Use 1/32-inch thick ABS, purchased at any plastic retailer. Test fit the disk to make sure that it covers the entire opening. Apply a thin bead of gap filling cement around the disks outer edge. Mount the disk on the backside of the hole. Most ABS comes with a textured side and a smooth side. Use either side. Allow 6 hours drying time.

3




Mix the body filler and cream hardener. The body filler should be mixed with the cream hardener in a 10-to-1 ratio, 10 parts filler to 1 part hardener. This is a general rule of thumb. Refer to the instructions on the side of the fillers can for the specific mixing ratio. Mix the body filler and cream hardener until an even color is reached. There should be no streaks of hardener visible. Mix only enough to fill one hole. Most body fillers start to harden after five to 10 minutes. Using a small putty knife, apply the mixed body filler to the hole. Smooth the filled area out with the putty knife. Allow one hour drying time.

4

Sand the body filler down until it is level with the parts surface. Sand the area down, by hand, with 120-grit sandpaper. Add additional filler to raise the level of the repaired area if needed. Sand again if necessary. Once the filled area is level with the parts surface, sand with 220-grit sandpaper. Wipe all dust and debris off of the repaired surface.

5

Spray the sanded area with auto primer. Use a standard gray automotive primer. Using painters masking tape, adhere old newspaper to the rest of the part to keep it from becoming covered with primer. Lightly sand the primed area with 600-grit sandpaper. Wipe down the sanded area with a rag to remove any sanding debris. After the primer dries, apply automotive paint matched to the parts color and the project is complete.