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Urethane Supply Company 6053 EZ-Weld Operating manual

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HOT AIR & NITROGEN WELDING
SET-UP AND USE GUIDE
A complete guide to setting up your new hot air &
nitrogen welding equipment and using it to make the
fastest, strongest, and most cost-effective repairs to
plastic bumper covers and other parts.
Copyright 2010 © Urethane Supply Company All Rights Reserved
Every step of the way, Urethane Supply Company has
what you need to repair and refinish plastics.
YOU WILL SUCCEED
Page 2 www.urethanesupply.com
Introduction





 
 
 
 




6053 EZ-Weld Hot Air Welder Setup and Use





Urethane Supply
Company DOES NOT warrant the heating elements
or any damage resulting from overheating of the ele-
ments or from damage caused by water or oil in the
air line.



















6053N2 Nitrogen –Air Controller Setup and Use




Temperature
Control Airow
Regulator
6050-NR1 welding tip
6175B Barrel & Nut Assembly
6062ME Replacement Heating
Element (inside barrel)
6100HW Hose &
Wiring Assembly
6053 EZ-Weld 2.0 Hot Air Welder - Controls & Replacement Parts
Page 3800.633.3047












































Plastic Identification – Can I Use the Hot Air Welder?







N2
6053
Hot Air
Welder
6053N2
Nitrogen-Air
Controller
Regulator (not supplied)
Purox R-36, P/N 21364
by ESAB Welding Products
(or similar)
Nitrogen bottle (not supplied)
rent from local welding supply
Compressed
Air
6053 / 6053N2
Setup Schematic
Push for Air
Pull for Nitrogen
Set up:
6KRS DLU 086TEH GU\ DQG RLOIUHH
5HJXODWH VKRS DLU DQG QLWURJHQ VXSSO\ WR
WKH VDPH SUHVVXUH ZKHQ VHOHFWRU NQRE LV
LQ HLWKHU SRVLWLRQ
TKHUH VKRXOG EH QR SHUFHSWDEOH FKDQJH
LQ DLU SUHVVXUH ZKHQ WKH VHOHFWRU YDOYH LV
LQ HLWKHU SRVLWLRQ
Use:
3XVK VHOHFWRU NQRE LQ WR ³DLU´ ZKHQ ZDUPLQJ RU
FRROLQJ WKH ZHOGHU RU ZKHQ WKH ZHOGHU LV LGOH
3XOO VHOHFWRU NQRE WR ³QLWURJHQ´ ZKHQ ZHOGLQJ
)RU EHVW UHVXOWV DOORZ  WR  VHFRQGV DIWHU
QLWURJHQ LV RZLQJ WR SXUJH DLU RXW RI WKH OLQH
EHIRUH ZHOGLQJ
1128 Kirk Rd.
Rainsville, AL 35986
ph: (800) 633-3047
www.urethanesupply.com
AIR
N
2
Air
Inlet
Nitrogen
Inlet
Outlet to
Hot Air
Welder
Balance pressure
regulators - adjust
to 40-50 psi
6053N2 Nitrogen-
Air Controller
Type of plastic Hot air weldable?
PP, PP/EPDM, TEO, TPO,
TSOP, PE, ABS, PA, PC YES
PUR, SMC, UP, fiberglass NO
Page 4 www.urethanesupply.com










Types of
plastic
Rod
Profile
PP, ABS,
PE, PA, PC,
PVC, TPO
PP, PE
PP, PE
PP, PE
PP, PE
PP
45°
Pressure
= 1 - 2 lb
Speed = 4 - 6 in/min
Temperature
= 550°- 600°F
Basic hot air welding process








temperature




angle


pressure



speed




Common Thermoplastics and Typical Applications
Plastic Symbol & Type Typical Applications Welding Rod
ABS instrument panels, grilles, trim moldings, street bike fairings ABS (R3)
PA - Polyamide, Nylon radiator tanks, mirrors, door handles, plastic engine parts PA (R6)
PC - Polycarbonate headlight lenses and housings PC (R7)
PC + ABS blend door skins, street bike fairings, instrument panels PC (R7) or ABS (R3)
PC + PBT blend (Xenoy) bumper covers (older Ford, M-B, BMW) PC (R7)
PE - Polyethylene over-flow tanks, windshield washer bottles, ATV & dirt bike
fenders, water storage tanks, kayaks & canoes
PE (R4, R18, R19,
R20, R21)
PP , PP/EPDM, TPO, TEO,
TSOP - Polypropylene Blends
bumper covers, side cladding & trim, filler panels, under-
hood parts, interior parts, snowmobile cowls
PP (R2, R5, R13,
R14, R15, R16, R17)
PPO + PA blend (Noryl GTX) fenders (GM), exterior trim PA (R6)
PVC - Polyvinyl Chloride pipe, siding, window frames, gutters, trim PVC (R9)
Page 5800.633.3047
Repairing a cracked bumper




 Clean the bumper before you grind it.














 Align the Outer (Cosmetic) surface







 Prep the backside of the crack






 Weld the backside of the crack






 Prep the front side for welding




Step B - Aligning the cosmetic outer surface
with aluminum tape
6485
Aluminum Tape
R14 or R16
PP Ribbon
Step D - Welding the backside of the crack with
PP ribbon rod
Step E - Preparing the front side for welding by
grinding a v-groove
Step A - Cleaning the plastic with 1000-A Super
Clean plastic cleaner
Page 6 www.urethanesupply.com
 Weld the front side of the crack









 Finishing the weld








Welding a broken bumper slot









 Clean the plastic first



 Taper the edges with sandpaper



 Apply tape to support rod during weld







Taper both
sides
R13
PP Ribbon
Step F - Welding the front side of the crack with R13 PP
ribbon
Step B - Tapering the edges of the slot to be repaired with sandpaper. Taper
both sides down so the rod has surface area to stick to once sanded.
Step C - Applying aluminum tape to support the melted welding
rod. You can also clamp a wooden stick underneath to provide
extra support.
Page 7800.633.3047
 Narrow the welding rod to width of bar.



 Weld across gap with ribbon






 Heat until rod turns clear and mash with hand seamer.







 Restore slot dimensions




 Weld opposite side



 Restore slot dimensions and finish repair. 



Recreating a tab with a “living hinge”






 Trace out the tab in the polypropylene sheet.




Step E - Welding across the gap with R13 PP rod
narrowed to the proper width.
Step F - Mashing the hot plastic flat and impress-
ing it into the bumper with the 6145 hand seamer
Step I - Restoring slot dimensions with a die
grinder and finishing the repair
Step A - Tracing out the shape of the tab on the
5010 PP sheet
Page 8 www.urethanesupply.com


 Create hinge line





 Notch back the bumper.


 Prep the bumper

 Tape the tab in position

 Weld the backside of the tab




 Prep the outer surface


 Weld the front side of the bumper



 Let cool and finish the repair


Step B - Create hinge line by bending
back-and-forth in a vise
Step B - Create corners by bending once
in the vise
Step C - Notch back into the bumper to
mount new tab
Step F - Weld the tab into place using the
R13 or R14 rod
Visit www.urethanesupply.com for videos and other instructional re-
sources. Check out our YouTube channel and become a fan on Facebook
for periodic plastic repair tips.
We are committed to providing the most complete information on plastic repair
and refinishing in the industry. Call 800-633-3047 for technical support,
Monday through Friday 7:00am - 4:00pm Central.
Urethane Supply Company
1128 Kirk Rd, Rainsville, AL 35986 USA
phone: 256-638-4103 fax: 256-638-8490