Urethane Supply Company 6053 EZ-Weld Operating manual
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 Airow
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:
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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
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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
This manual suits for next models
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