Kia Optima Bumper Cover Repair

A few months ago, we repaired a Kia Optima bumper cover that was damaged in an accident. A new bumper cover was not available and there was no estimate for when one would be back in stock. Using Polyvance plastic repair tools and equipment, we were able to repair the damage and recondition the bumper cover to like-new condition.

This video shows our repair process.

While this video focuses on repair process and technique, it is also a great example of a repair versus replace decision made under special circumstances. This bumper cover was heavily damaged. Under normal circumstances, it would be better for a shop to replace it because Kia Optima bumper covers are fairly inexpensive and readily available. However, when we repaired this bumper cover, they were not readily available. The owner of this vehicle could not find an OEM bumper cover (or even an aftermarket bumper cover) for the vehicle and was told there was no estimate for when one would become available. In this case, there was no other choice but to repair the bumper cover. Regardless of the circumstance, this nitrogen fusion welding technique can be used on any thermoplastic bumper cover - from inexpensive to very expensive.

Watch the full video above or view the photos of the process below.

The damage.

First, we cleaned the damaged area

We heated both sides of the bumper cover with a heat gun.

We used our Dent Driver tools to reshape the plastic.

After the plastic was reshaped, we aligned the cracks and applied hot staples using our plastic stapler to hold it in place. Then we applied aluminum tape over the staples.

We v-grooved both cracks and made a groove at the edge for our cross-stitch welds.

We welded both cracks with polypropylene welding rod and ribbon. Then we made the cross stitch weld at the ends.

We used the airless plastic welder along with the nitrogen plastic welder to smooth all the welds.

We v-grooved the cracks on the cosmetic side of the bumper cover.

We welded the cracks on the cosmetic side using the round 01 profile round welding rod.

We used the airless plastic welder along with the nitrogen plastic welder to smooth all the welds.

We sanded the welds on the cosmetic side.

We applied Flex Filler 2 over the welds on the cosmetic side.

We primed the bumper cover using 3043 Black Jack waterborne primer surfacer. We block sanded and primed again until we were satisfied with the appearance.

After shot of the bumper cover painted and installed on the vehicle.

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