MANUAL B6 PLASTIC WELDING SYSTEM

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 Using the
B6 PLASTIC
Using WELDING
the 5600HT SYSTEM
Airless Plastic Welder:

WARNING: Portable electric heating devices of the plastic weld-

ing type present certain inherent hazards.
The temperatures necessary for their normal use are high
enough to cause fire if they are left in contact with or near
combustible materials.
During normal operation the heating element, welding tip and plastic
materials are hot enough to cause severe burns even at the lowest pos-
sible temperature setting.
Never use near flammable liquids or vapors.

Electric shock hazard: Do not use in or near

water. Do not immerse in water. Do not use
if wet.

Do not use if cord, switch, or heating element

introduction B6 plastic welding system

are damaged. Never attempt servicing the

welder while plugged in.

During operation, use in a well ventilated area. Use a properly fitted

organic vapors respirator to prevent inhalation of vapors.
WARNING: This tool must be placed on its stand when not in use.

Introduction:
Before you begin:
Place “L” shaped metal welder stand on work bench with the “V” notch
up. Lay heating element in the stand so the element does not touch
any surrounding surface. Plug power cord into the control unit. Make
sure switch is in the off position, turning the knob counter-clockwise
until it stops. Plug unit into a power supply that matches the voltage
ratings of your welder. Turn the welder to the maximum temperature
setting. The heating element may smoke at this initial start-up as it
burns off the preservative oils on the elements components. It may
take several minutes for all the oils to burn off. This is normal. Turn
the temperature setting to the desired range for the material you are
welding. You are now ready to weld!

Changing the Welding Tip:

While cold, unscrew the existing tip out of the heating element. Screw
desired tip into the threaded end of the unit until snug. Do not over
tighten! Over tightening will make tip removal difficult or impossible.
Do not retighten tip while hot, unless it is excessively loose. Tightening
while hot will make removing the tip difficult or impossible.
If tip becomes fused into the element and the element is equipped with
a removable adapter, the adapter can be removed by loosening the
set-screw on the side of the element barrel. Additional adapters are
available if desired. Note: if your element does not have a set screw, it
has a non-removable threaded insert.

Cleaning the Welding Tip:

Immediately after welding, use the wire brush to remove as much
plastic from the tip as possible. Keeping the tip clean will ensure
cleaner welds and help reduce the amount of smoke produced after
the welding process is complete.
2
For technical assistance in the USA call:
(800) 633-3047 or go to
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Introduction
serving the needs ...........................................................2
of the plastic repair market, we have developed
a complete line of products thatRepair
Plastic Welding makesMethodall plasticChartrepair.................3
fast and
Plastic Identification Reference Chart ................4
easy. Thermoset Urethane Repair ................................5
Thermoplastic Fusion Weld Repair ....................6
FiberFlex Repair ...................................................7
Table of Contents:

Introductionplastic welding quick reference chart

...........................................................2
Plastic Welding Repair Method Repair Chart
Method .................3
Plastic Identification Reference Chart ................4
B C
A ................................5
ThermosetRepair
Urethane
Step Repair Page 5 Page 6 Page 7

ThermoplasticIdentify
FusionThermoset
Weld Repair ....................6
1 Plastic

plastic welding quick reference chart

ABS, PE, PA, PP, TPO, TEO,

FiberFlex Repair ...................................................7

Page 4
Polyurethane
(PUR)
PC, PP TPE, PE, or
other

2 Clean
Clean part with soap & water and Super
Clean Plastic Cleaner

plastic welding quick reference chart

Thermoset Thermoplastic
FiberFlex
Urethane Weld Fusion Weld

3 Repair Repair Method

A
Page 5-7 B C
Repair Step Page 5 Page 6 Page 7
4
Grind, then apply filler that matches
Fill the hardness of the substrate
Identify
1
Thermoset PP, TPO, TEO,
ABS, PE, PA,
Plastic Polyurethane
PC, PP TPE, PE, or

5
(PUR) Prime with a recommended Urethaneother
Page 4 Prime Supply Company primer.

2 Clean
Clean part with soap
3 & water and Super
Clean Plastic Cleaner

Thermoset Thermoplastic
Urethane Weld Fusion Weld FiberFlex

3 Repair

Page 5-7

4
Grind, then apply filler that matches
Fill the hardness of the substrate

5 Prime
Prime with a recommended Urethane
Supply Company primer.

3
3
 Plastic Identification Reference Chart
The easiest way to identify the type of plastic you’re working with is to
look for the plastic ID symbol on the backside of the part. Simply match
the symbol on the part with the table below and look at the suggested
repair method, listed in order of preference. See “The Book of Plastic
Repair” for tips when you can’t identify the plastic based on this chart
or find the plastic ID symbol.

Typical Applications
Recycling Symbol

Symbol & Type

How to Identify

Repair Method
Flexible bumper
PUR, RIM, RRIM Usually flexible, may be covers, filler panels,
Thermoset yellow or gray, bubbles & A or C
rocker panel covers,
Polyurethane smokes when melted.
plastic identification reference chart

Thermoset

snowmobile cowls.
Rigid, polyester matrix Rigid body panels,
SMC, UP, FRP fenders, hoods, deck NA
reinforced with glass
Fiberglass fibers, sands finely. lids, header panels, Adhesives
spoilers. Only

XPE, XLPE, PE-Xb, Usually semi-translucent, Gas tanks, kayaks,

PEX, Crosslinked waxy or greasy feel, canoes, trash cans, C
Polyethylene softens when heated but use is declining
does not melt.
ABS Rigid, often white but Auto interior panels,
Acrylonitrile Butadi-may be molded in any grilles, street bike fair- B
ene Styrene color, sands finely. ings, canoes, aircraft
interiors and wing tips.
PS Packaging material,
Semi-flexible, usually insulation, food NA
Polystyrene
(Styrofoam)
expanded into foam containers, light switch Adhesives
plates Only
Radiator tanks, head
PA Semi-rigid or rigid, lamp bezels, exterior
Polyamide (Nylon) sands finely. B
trim parts, mirrors,
plastic engine parts.
PC + ABS Door skins, instrument
Pulse, PC + PBT Rigid, sands finely, panels, street bike
Xenoy, (Polycar- usually dark in color. fairings, bumper B
bonate blend) covers
Semi-flexible, melts & All types of tanks, inner
HDPE smears when grinding, fenders, ATV fenders,
Polyethylene usually semi-translucent, kayaks canoes, picnic B
waxy or greasy feel. tables, lumber
Semi-flexible, melts & All types of tanks,
PE/LDPE smears when grinding, inner fender panels,
Polyethylene usually semi-translucent, ATV fenders, kayaks, B
waxy or greasy feel. canoes, trash cans
Semi-flexible, melts & Bumper covers, inner
PP smears when grinding, fenders, radiator
B or C
Polypropylene waxy or greasy feel, usu- shrouds, gas tanks,
ally a bit stiffer than PEs. battery cases, pallets
PPO + PA
Noryl GTX Semi-rigid, sands finely,
usually off-white in color. Fenders, exterior trim. B
(Nylon blend)
Thermoplastic

Rigid, sands finely. Pipe, siding, window

PVC Usually white or gray but frames, decking,
Polyvinyl chloride B
can be made any color gutters, speed bumps

TPE Semi-flexible, usually Bumper covers, filler

Thermoplastic black or gray, melts & panels, underhood C
Elastomer smears when grinding. parts.

TPO, TEO, Semi-flexible, usually Bumper covers, air

PP/EPDM, TSOP black or gray, melts & dams, grilles, interior
parts, snowmobile C or B
Thermoplastic Olefin smears when grinding.
cowls.
TPU, TPUR Bumper covers, soft
Thermoplastic Flexible, sands finely. filler panels, gravel B or C
Polyurethane deflectors, rocker
panel covers.
Soda bottles, various
PETE, PET
4 Polyethylene
Terephthalate
Flexible, strong
does not weld well
yarn fibers, headlin-
ers, fuse boxes, door B
panels

4
 Repair Method A: Thermoset Urethanes
Repair A:
Repair Method Method A: Thermoset
Thermoset Urethanes Urethanes
A: Thermoset
Repair MethodAutomotive urethane, or PUR,Urethanes
is a “thermoset” material. Like epoxy
Automotive
Automotive urethane, or urethane,
PUR, is a or type plastics,
PUR,
“thermoset” thermosetLike
is a material.
“thermoset” urethane
epoxy isLike
material. formedepoxy when two liquid chemicals
Automotive
type plastics,type urethane,
plastics,urethane
thermoset thermoset orformed
iscome PUR,
urethane iswhen
together ais“thermoset”
to
twoform
formed material.
a solid.
when
liquid twoTherefore,
chemicals liquid Like epoxy
you cannot melt urethane
chemicals
come together type
come plastics,
together
to form thermoset
to form
a solid. urethane
a solid.
Therefore, you is formed
Therefore,
cannot bumpers youwhen
melt withtwo
cannot
urethanethemelt liquid
welder. chemicals
urethane
come together
bumpers tothe
form
withbumpers welder.a with
solid.theTherefore,
welder. you cannot melt urethane
bumpers with the welder. The easiest way to identify thermoset urethane is to
The easiest way The easiest
to identify way thermoset press
to identify the heated
thermoset
urethane tip of theiswelder
is tourethane to into the plastic. If it
press the heated The easiest
press theway
tiptheofheated welderto
tipidentify
isthe
ofinto thermoset
thermoset
welder
the into
plastic. Ifurethane
urethane,
the it plastic. is to
it will Ifliquefy,
it bubble and smoke
is thermosetispress the heated
thermoset
urethane, urethane,
it will tip of(note:
liquefy, itthewillwelder
bubblewelderandinto
liquefy, must thebe
bubble
smoke plastic.
extremely
and If it hot for this to happen).
smoke
ismust
(note: welder(note: thermoset
welder urethane,
must behot
be extremely itfor
Upon willthis
extremely liquefy,
cooling,
tohot bubble
the
for
happen). and
“melted
this to smokewill remain tacky.
area”
happen).
Upon cooling, (note:
Upon welder area”
cooling,
the “melted must
the “meltedbe
willextremelyarea”tacky.
remain hotremain
will for thistacky. to happen).
Upon cooling, the “melted area” will remain tacky.

V-Groove Damaged Area

V-Groove
V-Groove Damaged
V-Groove Damaged
Area
Damaged Area
Area
• Line up the outer surface of the tear with 6481 Aluminum Body
• Line up the• outer
Line up the outer
surface tearTape.
of thesurface of the
with 6481tear with 6481
40900
Aluminum Aluminum
AluminumBody
Body Backing
Tape. • Tape.
Line up the outer surface of the tear with 6481 Aluminum Body
Tape. • Using a die grinder, V-groove halfway
• Using a die• grinder,
Using a V-groove
die grinder, through halfway
V-groove
halfway the backside of the part
through the• backside
Using a the
through die grinder,
part V-groove
backside
of the ofwith
theaparthalfway
6121-T Teardrop Cutter Bit or
through
with a 6121-Twith the
a 6121-T
Teardrop backside
40800Cutter
Garbide
Teardrop of the
grinding
Bit or part
Cutter tip
equivalent. Bit or
with a
equivalent. equivalent.6121-T Teardrop Cutter Bit or
equivalent. • Sand the v-groove with coarse
• Sand the •v-groove
Sand the coarse withsandpaper
withv-groove coarse (80 grit or coarser) to
•
sandpaper (80 Sand
sandpaperthe v-groove
(80 grittoor
grit or coarser) with
putcoarse
sometoextra “tooth” in the plastic.
coarser)

Repair method A - Thermoset Urethanes

sandpaper
put “tooth”
put some extra some extra (80 grit
in the“tooth”or coarser)
Also
plastic. in theremoveto the paint in the area
plastic.
put
Also removeAlso some
remove
the paint extra “tooth” in the
paint surrounding
thearea
in the plastic.
in the area the v-groove and radius
Alsov-groove
removethe
surrounding surrounding
the thev-groove
and paint in the
into
radius thearea
and v-groove for extra strength.
radius
surrounding
into the
into the v-groove for v-groovethe v-groove and
. strength.
for extra
extra strength radius
into the v-groove for extra strength.

Melt the Rod into the V-Groove

Melt theMelt
Rodthe
Melt intoRod
the theinto
Rod into the
•V-Groove
the
Set the V-Groove
V-Groove
temperature setting of your airless plastic welder to the
• Set the temperature
• Set the temperature setting of your “clear”
setting
airless oforplastic
“R1”airless
your rod setting.
welder plastic
to theUsing
weldertheto5003R1
the Polyurethane welding
• “clear”
“clear” or “R1”Set
rodthesetting.
ortemperature
“R1” Using setting
rod setting.
the rod, theof rod
Using
5003R1 your
the airless
should
40208
5003R1
Polyurethane plastic
come outwelder
of thetobottom
Polyurethane
welding the of the welder’s shoe
welding
“clear”
rod, thecome
rod, the rod should or “R1”
rod should rod setting.
out of comethecompletelyUsing
out ofofthe
bottom the
the 5003R1
melted
bottom and
welder’s Polyurethane
of clear,
the
shoe welding
not discolored
welder’s shoe or bubbling.
rod, the
completely rodclear,
should
melted come
notand out not
clear, of or
thebubbling.
bottom oforthe welder’s shoe
completely melted and
completely melted and • discolored
Holding
clear, not thediscolored
welder’s tip
discolored
bubbling.
oroff the surface
bubbling.
• Holding the• welder’s
Holding the welder’s
tip off tipofoff
the surface thetheplastic,
surface melt the rod into the
• of
of the plastic,Holding thethe
the plastic,
melt rodwelder’s
melt thetip
into the offinto
v-groove.
rod the thesurface
Don’t overheat the base
of the
v-groove.
v-groove. Don’t plastic,
overheat Don’t melt
the thematerial,
overheat
base rodthe intobase
the
simply melt the rod onto the
v-groove.
material,
material, simply melt the Don’t
rod overheat
simply melt
onto the the theonto
surface.
rod base
Again,
the you are NOT trying to
material,
surface.
surface. Again, you are simply
Again,
NOTyou melt
trying the
are melt rod
toNOT theontorod the
trying and
to the bumper together;
surface.
melt the rod melt
and Again,
the bumper
the rod andyou the are theNOT
bumper
together; bumper tryingmaterial
together; to is NOT meltable!
meltbumper
the
the bumper material theisrod andmeltable!
material
NOT the isbumper
NOTdown together;
meltable!
•
the bumper material is NOT meltable!Lay no more than 2 inches of
• Lay down•noLay more downthanno2 more
inchesthan ofwelding
2 inches rodofinto the v-groove at a time.
welding rod• into
Lay the
weldingdown rodnointo
v-groove more at than
the av-groove
time. 2 inches
Remove a of
atthe rod from the welder tip, and before the melted rod has
time.
welding
rod fromrod
Remove the Remove theinto
the rod the tip,
from
welder v-groove
time
the welder
and at atip,
tobefore
cool time.
down, go back
andmelted
the before the
rod over it withrod
melted
has thehas
hot welder tip and smooth
Remove
time
time to cool down, togo coolthe rod
down,
back from
over the the
out
goit with
back welder
over
the hotittip,
weld. withand
Don’t
welder before
overheat
thetip
hotand the
welder melted
the
smooth androd
tipbase has .
material
smooth
time
out the weld.out tooverheat
the
Don’t cool down,
weld. thego
Don’t back
overheat
base over it.withmaterial
the base
material the hot.welder tip and smooth
out the weld. Don’t overheat the base material.

V-Groove and Weld Opposite Side

V-Groove
V-Groove
V-Groove and
and Weld
and• Weld
After theOpposite
Opposite
Weld Side
Opposite
weld Side
Sidecools, repeat the v-grooving and
on the backside
• After
• After the weld weld on the
on the backside welding
cools, repeatprocess
backside cools, on thethe
repeat
the v-grooving opposite side.and
v-grooving
and
• welding
Afteronthethe
welding process weld onon
process thethe
opposite backside
oppositecools,
side. side. repeat the v-grooving and
welding process on the opposite side.

Grind Weld to a Smooth Contour

Grind
Grind Weld toWeld
Grind to
to• aaUsing
a Smooth
Weld Smooth
Contour
Smooth Contour
Contour
coarse sandpaper, grind weld
• Using coarse• Using coarse grind
sandpaper, sandpaper,weld to agrind
smooth contour. The urethane
weld
to a smooth • to
Using coarse
a smooth
contour. sandpaper,
Thecontour.
urethane welding
The grindrod
urethaneweld
will not feather very well,
to a
welding
welding rod will smooth contour.
rod willvery
not feather not featherThe
well, urethane
so it will
veryneed
well,to be covered with 2000
welding
so it will needsotoit be rod will
willcovered
need not
to with feather
be covered
2000 very
with well,
Flex-Filler 22000
epoxy filler to refinish
so it will
Flex-Filler 2 Flex-Filler need
epoxy filler2toepoxy to be
refinish covered
to refinish2000
with
fillercompletely. Grind the weld slightly
Flex-Filler
completely.
completely. Grind 2
the weld epoxy
Grind filler
the weld
slightly to refinish
flush slightly
so that filler can cover the welded
completely.
flush so that flush so that
filler can Grind the
fillerthecan
cover weld completely.
area
cover
welded slightly
the welded
flush so that filler can cover the welded
area completely.
area completely.
area completely. 5
5
5 55
 Repair Method B: Fusion Welding
Outside of urethane, all other bumpers, and most
other plastics on automobiles, are made from
thermoplastic materials. This means they can be
melted with the application of heat. Thermoplastic
parts are made by melting pellets of plastic
and squirting the melted material into a mold,
where it cools and resolidifies. This means that
thermoplastic parts can be melted. Thermoplastic

V-Groove Damaged Area

• Line up the outer surface of the tear with 40900 AluminumBody
6481 Aluminum Backing
Tape.
• Using a die grinder, V-groove halfway
through the backside of the part
40800 Garbide
with a 6121-T Teardropgrinding tip or
Cutter Bit
equivalent.
• Remove the paint in the area
surrounding the v-groove and
Repair method B - Fusion Welding

radius into the v-groove with coarse

sandpaper.

Melt the Rod Together with the Base Material

• Set the temperature setting of your airless plastic welder to the
setting that’s appropriate for the welding rod you selected in the
identification process. In most cases, the welding rod should melt
cleanly and not be discolored (the only
exception would be nylon, where the rod
should turn a light brown).
• Lay the welder tip on the surface of the
plastic and slowly melt the rod into the v-
groove. Pull the welder toward you so you
can see the welding rod fill the v-groove as
you make your pass.
• Lay down no more than 2 inches (5 cm) of welding rod into the v-
groove at a time. Remove the rod from the welder tip, and before the
melted rod has time to cool down, go back over it with the hot welder
tip and thoroughly melt the rod together with the base material. It
helps to press into the plastic with the edge of the welder tip to mix
the materials, then go back and smooth it out. Keep the heat on it
until you have a good mix between the rod and base.

V-Groove and Weld Opposite Side

• After the weld on the backside cools, repeat
the v-grooving and welding process on the
opposite side.

Grind Weld to a Smooth Contour

• If you need to refinish the plastic, grind
weld to a smooth contour with coarse
sandpaper. Grind the weld slightly flush
6 so that filler can cover the welded area
completely.

6
 Repair Method C: FiberFlex Rod C:
Repair Method FiberFlex Rod
RepairRepair
Method C: FiberFlex
Repair
Method C:Method Rod
FiberFlex
C: FiberFlex
Rod Rod
FiberFlex is a unique repair material FiberFlex in that it sticks to any repair
is a unique plasticmaterial
sub- in that it sticks to any plas
FiberFlexFiberFlex
is a unique is arepair
FiberFlex
uniquematerial is ain
repair unique
that it repair
strate.
material sticks
inIt that to
material
is notit any plastic
a true
sticks in that
anysub-
welding
to itplastic
sticks tostrate.
rod, but
sub- any plastic
rather notsub-
Itaisthermoplastic adhesive.
a true welding rod, but rather a thermoplastic ad
strate. It is not a true welding
strate.rod,
It is but
not
strate. It is not a true welding rod, rather
a true a
welding
FiberFlex thermoplastic
but rather rod, but adhesive.
hasaathermoplasticrather
very strong bond a thermoplastic
andFiberFlex
adhesive. adhesive.
is reinforced
has awith
verycarbon
strongandbond and is reinforced with carbon
FiberFlexFiberFlex
has a very strong
FiberFlex
bond has
and
has a very strong bond a
is very
reinforced
glass strong
andfibers with
bond carbon
and
for outstanding
is reinforced is and
reinforced
with carbon strength. with carbon and
andglass fibers for outstanding strength.
glass fibers
glassforfibers
outstanding
for glass
strength.
fibers for
outstanding outstanding
FiberFlex isstrength.
strength. the best way to repair the most common automotive
FiberFlex is the best way to repair the most common automoti
FiberFlexFiberFlex
is the best is way to repair
theFiberFlex
best wayistothe
the most
bumpercommon
bestthe
repair way material,
most automotive
to repair
commonTPO (aka TEO,
the most
automotive common PP/EPDM,
automotive
bumper TSOP). TPO (aka TEO, PP/EPDM, TSOP).
material,
bumper material, TPO (aka
bumperTEO,
bumper material, TPO (aka TEO, PP/EPDM,
material, TPO TSOP).
(aka
PP/EPDM,
FiberFlex TEO, PP/EPDM,
TSOP).
can also TSOP).
be used to repair FiberFlexvirtually any canplastic.
also beIt used
will stick to virtually any plastic. It will
to repair
FiberFlexFiberFlex
can also canbe used to
berepair
FiberFlex
also used virtually
canto also beany
urethanes
repair used plastic.
virtuallyand
to any Itplastic.
Xenoy,
repair will stickItWhen
too.
virtually toanystick
will youurethanes
toareItnot
plastic. willsure
andwhat
stick to typetoo.
Xenoy, of When
plastic you are not sure what type o
urethanesurethanes
and Xenoy, andtoo. When
urethanes
Xenoy, you
too.and are
When younot
Xenoy, are
you sure
too.
are what
repairing,
When
not type
sureyou ofareplastic
trywhat
FiberFlex.
not sure
type what
you type
of plastic of plastic try FiberFlex.
are repairing,
you are repairing, try FiberFlex.
you are repairing, youtryareFiberFlex.
repairing, try FiberFlex.

V-Groove Damaged Area V-Groove Damaged Area

V-Groove Damaged
V-Groove Area•Damaged
V-Groove
Damaged Area Area
Line up the outer surface of the tear with up the outer surface of the tear with
• Line
• Line up• the
Lineouter surface
up the • Line
outer ofsurface
the tear
up the with
the6481
ofouter surface
tear Aluminum
withof the tearBodywith Tape. 6481 Aluminum Body Tape.
6481 Aluminum Body Tape. 40900
6481 AluminumBody
BodyAluminum Backing Tape
6481 Aluminum Tape. • Using Tape. a die grinder, remove plastic• inUsing a die grinder, remove plastic in
• Using •a die grinder,
Using a die remove
• Usingplastic
grinder, a die in
remove the shape
grinder,
plastic in ofplastic
remove a broadin V-groove halfway the shape of a broad V-groove halfway
the shapethe of shape
a broad of V-groove
a the
broad shapehalfway through
of a broad
V-groove halfway the backside
V-groove halfwayof the part withthrough
a the backside of the part with a
through the backside of the
through part with
the
through the backside of the part with a a 6122,
backside 6122NF,
of the part 6134-R
with a round cutter bit 6122NF, 6134-R round cutter bit
6122,
6122, 6122NF, 6134-R round
6122, cutter
6122NF,
6122, 6122NF, 6134-R round cutter bit bit or equivalent.
6134-R round The
cutter v-groove
bit should be about
or equivalent. 3 to 4The
cm wide whenshould be about 3 to 4 cm wide
v-groove
or equivalent. The v-groove
or equivalent. or should beshould
Theequivalent.
v-groove about
finished.
The 3 toabout
v-groove
be 4 cm 3wide
shouldto 4bewhen
cm about
wide 3when
to 4 cm wide when
finished.
finished. finished. finished.

Repair method C - Fiberflex Rod

• It is very important to put some “tooth” • It isinvery
the plastic by grinding
important to put some “tooth” in the plastic by grind
• It is very important to• put
• It is very important It some
is very “tooth”
to put someinthe
important the
“tooth” plastic
tov-groove theby
putinsome withgrinding
50 grit
“tooth”
plastic or
thecoarser
plastic sandpaper.
byingrinding by v-grooveUse
thegrinding witha low speed
50 grit or coarser sandpaper. Use a low s
the v-groove with 50 grit or
the coarser
v-groove sandpaper.
withgrinder.
50 grit Use
or a
Grindinglow
coarser atspeed
high speed
sandpaper. will
Use tend
a low to melt
speed many thermoplas-
the v-groove with 50 grit or coarser sandpaper. Use a low speed grinder. Grinding at high speed will tend to melt many therm
grinder. Grinding at high speed
grinder. will tend
Grinding to
tics.
at melt
high many
speed thermoplas-
will
grinder. Grinding at high speed will tend to melt many thermoplas- tics. tend to melt many thermoplas-
tics. tics. tics. • With 80 grit paper in a DA sander,• feather thegrit
paint intointhe area
With 80 paper a DA sander, feather the paint into the
• With 80 grit paper in a
•
• With 80 grit paper DAWith sander,
in80 gritfeather
a DA paper
sander, the
around
in a paint
DA
feather intopaint
thesander,
v-groove
the thefeather
area
and radius
thearea
into the the into
paint edges
aroundtheofarea
thev-groove
the v-grooveand smoothly.
radius the edges of the v-groove s
around the v-groove and radius
around the
the edges
v-groove of the
and v-groove
radius
around the v-groove and radius the edges of the v-groove smoothly. the smoothly.
edges of the v-groove smoothly.

Melt on the FiberFlex Melt on the FiberFlex

Melt on theonFiberFlex
Melt Melt
the on the
FiberFlexFiberFlex
• With the airless welder set to the • With the airless welder set to the
• With the airless
• With thewelder • set
airless With tothe
welder theset
airless
to thehighest
welder set temperature
to the setting, use the highest temperature setting, use the
highest temperature setting,
highest use the
temperature
highest temperature setting, use the 6028RT Round
setting, use Tip
the to melt the 5003R106028RT Round Tip to melt the 5003R10
6028RT Round
6028RTTip to melt
Round Tipthe
6028RT
40210 to 5003R10
Round
melt the FiberFlex
Tip to meltwelding
5003R10 40209
the 5003R10 rod onto the surface. FiberFlex welding rod onto the surface.
FiberFlexFiberFlex
welding rod onto the
FiberFlex surface.
welding
welding rod onto the surface. Bestrod adhesion
onto the is achieved
surface. by pre- Best adhesion is achieved by pre-
Best adhesion is achieved Best by pre-
adhesion
Best adhesion is achieved by pre- ismelting
achieved one byside
pre- of the end of the rod,
melting one side of the end of the rod,
melting one side of the end of
melting the
onerod,
melting one side of the end of the rod, side then
of theflipping
end ofthe
the rodrod,over so that the then flipping the rod over so that the
then flipping the rod over so
then that the
flipping
then flipping the rod over so that the the melted
rod over portion
so thatsticks
the to the plastic. Cut
melted portion sticks to the plastic. Cut
melted portion sticks to the
meltedplastic. Cut
portion
melted portion sticks to the plastic. Cut the
sticks melted
to the part of
plastic. the
Cut ribbon off usingthe melted part of the ribbon off using
the melted part of the ribbon
the off
melted using
the melted part of the ribbon off usingpart the
of theedgeribbonof the
off welder
using tip and spread the edge of the welder tip and spread
the edgetheof the welder tip
theand
edge spread
of
edge of the welder tip and spread the the
welderFiberFlex
tip and into
spread the v-groove. Do the FiberFlex into the v-groove. Do
the FiberFlex into the v-groove.
the Do
FiberFlex
the FiberFlex into the v-groove. Do intonottheattempt
v-groove. to melt
Do the base material not attempt to melt the base material
not attempt to melt the base
not material
attempt
not attempt to melt the base material to together
melt the with
base the
materialFiberFlex. Repairing together with the FiberFlex. Repairing
together together
with the FiberFlex. Repairing
together with
with the FiberFlex. Repairingthe with Fiber-Flex
FiberFlex. is
Repairingsimilar to a brazing with Fiber-Flex is similar to a brazing
with Fiber-Flex is similar to
with a brazing
Fiber-Flex
with Fiber-Flex is similar to a brazing process.
is similar to a brazing process.
process. process. process.

V-Groove and Weld Opposite V-Groove Sideand Weld Opposite Side

V-Groove and V-Groove
V-GrooveWeld Opposite
and Weld•and Side
AfterWeld
Opposite
the Opposite
Side
FiberFlex Sidecools (you may force cool with
on the backside
• After the FiberFlex on the backside cools (you may force co
• After the FiberFlex
• After on• the backside
After
the FiberFlex thethe
on cools
FiberFlex (you
water),
backside may
oncoolsrepeat
the force
the
backside
(you maycool with(you
v-grooving
cools
force cooland
withwelding
may force
water), process
cool with on
repeat thethe oppositeand welding process on the op
v-grooving
water), repeat
water),the v-grooving
repeat water),
the and welding
repeat
v-grooving the
and process
side.
v-grooving
welding on
Build the the
and
process opposite
FiberFlex
welding
on theslightly
processhigher
opposite onside.than
the thethe
surface.
opposite
Build FiberFlex
FiberFlex slightlyis higher than the surface. Fib
side. Build theBuild
side. FiberFlex slightly
the side.
FiberFlex higher
Build than
also athesandable
the FiberFlex
slightly higher surface.
slightly
than FiberFlex
filler.
thehigher
surface.than isthe surface.
FiberFlex also FiberFlex
is a sandableis filler.
also a sandable filler. also
also a sandable a sandable filler.
filler.

Finish Sand Finish Sand

FinishFinish
Sand Sand
Finish Sand
• After allowing the FiberFlex to cool• After allowing the FiberFlex to cool
• After allowing
• After the FiberFlex
allowing • the
After toallowing
cool tothe
FiberFlex completely, sand
FiberFlex to
cool coolwith 80 grit paper incompletely, sand with 80 grit paper in
completely, sand withsand
completely, 80completely,
grit
withpaper in
sand
80 grit a with
paper DAinsander at low in
80 grit paper speed. Progress atoDA sander at low speed. Progress to
a DA sandera DAatsander
low speed.
atalow
DAProgress to low
finerspeed.
sanderProgress
speed. at grits,
to ending
Progresswithto320 grit. finer grits, ending with 320 grit.
finer grits,finer
ending
grits,with 320 grit.
finerwith
grits,
320ending
grit. with 320 grit.
ending
7
7 7
7 7 7
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