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How I use my 80 watt Plastic Welding Kit

Article wrote by James Frampton

How to article

How to use a plastic welder was something I had no idea of until a few days ago. I had some damage on my front bumper of my Nissan. A tear or crack started from close to the bottom of the grill and ran down about 5 or 6 inches long.

Also, just below that damage is another crack that runs close to where the fog light housing is, and runs down to the end of the bottom valance. With over ten years of auto body work experience, I figured that I could use the plastic welding kit without any instructions.


What time could be better than now, to purchase that Plastic welder you have been wanting? 

So I decided to purchase one from Harbor Freight. It is an 80 watt Iron Plastic welding kit made by Chicago Electric company.

This particular plastic welder has a maximum heat of 525-degree Fahrenheit.

This plastic welder cost around $15 dollars.


The plastic welding kit includes the following:

  1. 80 watt welding iron
  2. standard multipurpose welding rod
  3. steel wire mesh
  4. wire brush

This plastic welding kit sku # is 60662 if you want to purchase one yourself at Harbor Freight.

The plastic welding filler rods will weld plastic car or truck bumpers that are made out of the following:

  1. TPO - Thermoplastic polyolefin
  2. PP - Polypropylene
  3. PE - Polyethylene


This plastic welder includes repair sticks, steel wire mesh, welder stand, and wire brush. View all tools below.

This iron tip will reach 525 degrees F.


Box label of the plastic welder

Using a plastic welder to repair a cracked car bumper video

Plastic welding kit

Step by step on how to use a plastic welder

If you want to try and fix your damaged automobile bumper or any plastic valance on your own, keep reading.

I will describe each step I did to repair my Nissan front bumper cover.

Before we start, the tool I used and will be describing how to use in this article is a Chicago Electric, 80 watt iron plastic welder from Harbor Freight.


Step One.

First you must determine what the damaged area will need to be repaired correctly. If the damage is just a simple tear and has no missing pieces, Simply add the melt the welding filler rod into the length of the tear.

If parts of the bumper were torn off and the piece is missing, you will have to get something behind the damaged area in order to fill that place with the filler rod material.This will require more work and more filler strips to finish the job.


Step Two.

In my case, the damage was a simple tear in the bumper. So I cleaned four or five inches around the tear with a cleaner to remove all dirt and debris from the area. Just make sure the area is completely clean.


Step Three.

If you can get behind the damage weld the underside of the damaged area and top side as well. 

In my case, removing the complete bumper cover would require more time and work. Also, I needed my car for work that day, so I decided to just weld the top side of the damaged area and add more filler material to the tear.

You will have to decide for yourself what direction you will use for this step.


Step Four.

Make sure your Plastic welding iron has been turned on for at least several minutes so that it has reached its maximum heat.

Once it's reached its maximum heat you can then begin to weld.

The maximum heat on my plastic welder is 525 degrees f. 


Step Five.

Make sure you get the tear flush and aligned correctly. This step is very important. You don't want to weld having the two sides mis-aligned. Once flushed and aligned begin by tack welding the top, middle and bottom of the tear.

You can use a flat head screwdriver to hold the two pieces flush as your applying the tack weld.

After you have the top, middle and bottom tacked and even then start applying the filler rods and melting them onto the tear and spreading evenly on the damaged area.

Try to keep the build-up to a minimum, that way it will not require as much sanding as it will if you have too much filler rod material on the cracked area.


Step Six.

Once you have welded the damaged area, let it cool for several minutes and then push and pull around the area to make sure the area is fused together correctly.

After you know that the area has been welded correctly, you can then get you some 320 grit sandpaper and start sanding down the high build-up of the filler rod. Once you have removed the bulk of the build-up, use 400 grit and a sanding block to finish up the area.

If you have a low area, simply apply more filler to that area. Once you have gotten it straight and flushed with the surrounding panels you are then ready for body filler.


Step Seven.

After completing the body filler, all that is needed is primer and paint. You can be satisfied that YOU have now saved yourself hundreds of dollars in repair cost. And you did it yourself.

You had fun accomplishing something important and saved big bucks.

80 watt iron plastic welding kit from Harbor freight.

This is the Iron that come in the kit. This will get to 525 degrees

Plastic welding kit

wire screen mesh included in the plastic welding kit, gang. 

plastic filler rods included.

plastic welding iron metal holder.

Also in the kit come this steel wire brush.

Close up photo of the plastic welding iron tip.

Don't break that tip off or the iron welder will be a big paper weight.