Plastic welding Air intake - ZR-1 Net Registry Forums

LGAFF · 01-03-2014

Bought this from a form member its an AO engineering intake, the neck was really bust up on it and filled with JB weld which was falling out. I bought a $16 Plastic Welder from Menards...the one that looks like a soldering iron, and used that and my heat gun to melt the welding rods...

Right now it looks rough, but this is without much prep, needs some more attention, but it seems to have bonded well and it is functional. I will go back and add in some in a few areas and then hand sand it smooth.

Areas were there is a gap I backed with aluminum tape and bridged it across

Before; JB Weld removed and plastic angled

Welded up

Minor Clean up

LGAFF · 01-03-2014

Inside; still needs clean up

fletchusmc · 01-03-2014

Looks like that should turn out great

LGAFF · 01-03-2014

Looking at some OE intakes the material is polyethylene plastic; so you would probably want HDPE welding rod or strips

scottfab · 01-04-2014

what temp does the welding iron run at?
Do you have a way to measure it?
I'm curios because I need to repair a small crack in mine.
It's been there for at least 17yrs and I want to repair it.
I have a temperature controlled soldering iron that I can
dial up what ever temp I want. Hoping to use it.

Where do you get the plastic welding rods?
Is there a chance a piece could break off
and get sucked into the valves? What I mean is,
is the bond as strong as the original plastic?
If it were to be flexed to the breaking point would
it break at the bond location or somewhere else first?

LGAFF · 01-04-2014

The welder runs at 525 degrees and has a flat face on it....if prepped correctly and using a good rod, no the stuff will not come off. I would get the HDPE stuff, probably from granger or a body shop supply store. I saw a bumper repair demo and after it was repaired, we tried to rip it, could not do it.

WVZR-1 · 01-04-2014

The back-side of the AC housing will have the material composition molded in it. I would think you should expect HPDE and use the appropriate rod. Were all housings HPDE? I'd look first but I would think so. So long as the correct/compatible rod is used you should expect a good repair.

LGAFF · 01-04-2014

01-03-2014	#1
LGAFF Join Date: Mar 2007 Location: Crystal Lake, IL Posts: 7,194	Plastic welding Air intake Bought this from a form member its an AO engineering intake, the neck was really bust up on it and filled with JB weld which was falling out. I bought a $16 Plastic Welder from Menards...the one that looks like a soldering iron, and used that and my heat gun to melt the welding rods... Right now it looks rough, but this is without much prep, needs some more attention, but it seems to have bonded well and it is functional. I will go back and add in some in a few areas and then hand sand it smooth. Areas were there is a gap I backed with aluminum tape and bridged it across Before; JB Weld removed and plastic angled Welded up Minor Clean up __________________ LGAFF 90 #966-150K miles-sold 92 #234-sold 1987 Callaway TT #17 1991 ZR-1 #1359

01-03-2014	#2
LGAFF Join Date: Mar 2007 Location: Crystal Lake, IL Posts: 7,194	Re: Plastic welding Air intake Inside; still needs clean up __________________ LGAFF 90 #966-150K miles-sold 92 #234-sold 1987 Callaway TT #17 1991 ZR-1 #1359

01-03-2014	#3
fletchusmc Join Date: Nov 2013 Location: Jacksonville, NC Posts: 48	Re: Plastic welding Air intake Looks like that should turn out great

01-03-2014	#4
LGAFF Join Date: Mar 2007 Location: Crystal Lake, IL Posts: 7,194	Re: Plastic welding Air intake Looking at some OE intakes the material is polyethylene plastic; so you would probably want HDPE welding rod or strips __________________ LGAFF 90 #966-150K miles-sold 92 #234-sold 1987 Callaway TT #17 1991 ZR-1 #1359

01-04-2014	#5
scottfab Join Date: Jan 2009 Location: Portland Oregon metro area (Washington side) Posts: 3,207	Re: Plastic welding Air intake what temp does the welding iron run at? Do you have a way to measure it? I'm curios because I need to repair a small crack in mine. It's been there for at least 17yrs and I want to repair it. I have a temperature controlled soldering iron that I can dial up what ever temp I want. Hoping to use it. Where do you get the plastic welding rods? Is there a chance a piece could break off and get sucked into the valves? What I mean is, is the bond as strong as the original plastic? If it were to be flexed to the breaking point would it break at the bond location or somewhere else first? __________________ Scott Vett owner since 1979._It's about the car and the people

01-04-2014	#6
LGAFF Join Date: Mar 2007 Location: Crystal Lake, IL Posts: 7,194	Re: Plastic welding Air intake The welder runs at 525 degrees and has a flat face on it....if prepped correctly and using a good rod, no the stuff will not come off. I would get the HDPE stuff, probably from granger or a body shop supply store. I saw a bumper repair demo and after it was repaired, we tried to rip it, could not do it. __________________ LGAFF 90 #966-150K miles-sold 92 #234-sold 1987 Callaway TT #17 1991 ZR-1 #1359

01-04-2014	#7
WVZR-1 Join Date: Oct 2004 Posts: 1,890	Re: Plastic welding Air intake The back-side of the AC housing will have the material composition molded in it. I would think you should expect HPDE and use the appropriate rod. Were all housings HPDE? I'd look first but I would think so. So long as the correct/compatible rod is used you should expect a good repair.

01-04-2014	#8
LGAFF Join Date: Mar 2007 Location: Crystal Lake, IL Posts: 7,194	Re: Plastic welding Air intake __________________ LGAFF 90 #966-150K miles-sold 92 #234-sold 1987 Callaway TT #17 1991 ZR-1 #1359