Volkswagen ID.4: Welding plastic attachments

• Welding crack up to length of 100 mm
• Welding tab

Welding crack up to length of 100 mm

• ⇒ Rep. gr. 52 ; Repair deformations .

Important

• Both sides of the crack must face each other in relieved condition.

• ⇒ Rep. gr. 52 ; Preparing plastic repair .
• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .

Painted plastic attachments

• Sand repair area with a commercially available orbital sander -A- and P120 grit sandpaper.
• Blow out sanding residues.

• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products

All vehicles (continued)

If the plastic attachment does not have a small thickness

• Use a commercially available conical milling cutter -B- to mill a V-shaped bevel on the inside and outside along the crack -arrow-.
• Blow out milling residues.
• Align crack -arrow- flush.

Continued

• Insert wedge-shaped welding nozzle -B- into hot air blower -A-.
• Use wedge-shaped welding nozzle -B- at welding temperature to spot weld plastic attachment along crack -arrow-.

Important

• The contact line of the wedge-shaped welding nozzle -Bmust be guided parallel to the surface.
• If the contact line of the wedge-shaped welding nozzle -B- is not guided parallel to the surface, material will be removed.

Note

The first welding pass is carried out without applying material to create a connecting line between the edges of the crack. The connecting line is the basis for the material application.

• Use a commercially available knife -A- to bevel end of welding rod -1-.
• Make sure that welding rod -1- is clean and in good condition.

• Insert adapter nozzle for welding -B- into hot air blower -A-.
• Place welding rod -1- with bevelled side at end of crack.
• Move hot air blower -A- in a wagging motion.
• Use hot air blower -A- to heat up welding rod -1- an body attachment until welding rod -1- and body attachment become soft at the same time.
• Push welding rod -1- into area of crack to apply material.

Important

• The pressure on the welding rod -1- must be sufficient such that the welding rod -1- can bond with the body attachment.

  The welding rod -1- must not deform or break the V-shaped bevel.

• Guide welding rod -1- vertically along the path of the crack.

Important

• Welding rod -1- must be held at an angle of 80º to 90º to the surface.

• Move hot air blower -A- along the crack.
• Select welding speed so that:

• the material does not decompose or deform.
• the welding rod -1- bonds with the body attachment.

After the crack has been welded:

• Allow body attachment to cool down.
• Separate excess welding rod.

Continued

• Repeat the procedure on the other side of the body attachment.
• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .
• Use a commercially available conical milling cutter -B- to remove excess material from weld seam -arrow-.
• Blow out sanding residues.

• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .
• Sand repair area with a commercially available orbital sander -A- and P120 grit sandpaper.
• Blow out sanding residues.
• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .

• Apply primer -A- ⇒ Rep. gr. 52 ; Processing instructions - original products .

• Apply 2 cm of adhesive bead -arrow- on test piece.
• Make sure that both components of the plastic adhesive -Aare completely mixed.
• Apply plastic adhesive -A- ⇒ Rep. gr. 52 ; Processing instructions - original products .
• Use a commercially available spatula to spread adhesive bead -arrow-.

• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .
• Sand repair area with a commercially available orbital sander -A- and P150 grit sandpaper.
• Blow out sanding residues.
• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .

Welding tab

• ⇒ Rep. gr. 52 ; Preparing plastic repairs
• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products
• Use a commercially available conical milling cutter -B- to mill a V-shaped bevel on the inside and outside along the crack -1-.
• Blow out milling residues.
• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .

• Insert wedge-shaped welding nozzle -B- into hot air blower -A-.
• Align tab -1- flush.

• Use wedge-shaped welding nozzle -B- and hot air blower -A- at welding temperature to spot weld tab along its entire length.

Important

• The contact line of the wedge-shaped welding nozzle -Bmust be guided parallel to the surface.
• If the contact line of the wedge-shaped welding nozzle -B- is not guided parallel to the surface, material will be removed.

Note

The first welding pass is carried out without applying material to create a connecting line between the edges. The connecting line is the basis for the material application.

• Use a commercially available knife -A- to bevel end of welding rod -1-.
• Make sure that welding rod -1- is clean and in good condition.

• Insert adapter nozzle for welding -B- into hot air blower -A-.
• Place welding rod -1- with bevelled side.
• Move hot air blower -A- in a wagging motion.
• Use hot air blower -A- to heat up welding rod -1- and tab -2- until welding rod -1- and tab -2- become soft at the same time.
• Push welding rod -1- into area of crack to apply material.

Important

• The pressure on the welding rod -1- must be sufficient such that the welding rod -1- can bond with the body attachment.

  The welding rod -1- must not deform or break the V-shaped bevel.

• Guide welding rod -1- vertically along the path of the crack.

Important

• Welding rod -1- must be held at an angle of 80º to 90º to the surface.

• Move hot air blower -A- along the crack.
• Select welding speed so that:

• the material does not decompose or deform.
• the welding rod -1- bonds with the body attachment.

After the crack has been welded completely:

• Allow body attachment to cool down.
• Separate excess welding rod.

Continued

• Repeat the procedure on the other side of the body attachment.

• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .
• Use a commercially available conical milling cutter -B- to remove excess material from weld seam -1-.
• Blow out sanding residues.

• Clean repair area with plastic cleaner ⇒ Rep. gr. 52 ; Processing instructions - original products .