Mazda 6. Manual - part 420

PLASTIC BODY PARTS 

VI–3

VI

REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS

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The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been 
damaged greater than this could also be repaired, it should be replaced with a new one because such repair would 
detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of 
work time.

Repairable Bumpers

1. A bumper with a hole less than 50 mm {1.97 in} in 

diameter.

2. A bumper with a crack less than 100 mm {3.94 in} 

in length.

3. A bumper with a crack less than 100 mm {3.94 in} 

in length that is less than half of the width of the 
bumper.

End Of Sie

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PLASTIC BODY PARTS 

POLYPROPYLENE BUMPER REPAIR

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End Of Sie

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PLASTIC BODY PARTS 

VI–5

VI

PROCEDURE

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Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too 
serious to be restored by painting only.

1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make 

an angle of about 45

°.

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PLASTIC BODY PARTS 

2. Weld the damaged area.

• For repair of a cracked area, melt the crack together with a heat gun and a melting attachment.

• For repair of a hole, degrease the area on both sides of the bumper and apply aluminium tape on the 

reverse side of the damage area.

3. Melt the polypropylene welding rod with a heat gun and deposit it the cracked area.

Note

• Heat the shaded area to melt it.

• Take care not to overlay melt welding rod. If the part is welded with the welding rod melted like jelly, the 

welding strength will be reduced.

• Hold the heat gun 10—20 mm {0.39—0.79 in} from the part being welded.

• Do not move the welding rod until the welded parts cool.

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