8003 Nitro-Fuzer Setup and Use

This is the setup and use video for the 8003 Nitro-Fuzer® nitrogen plastic welder. This welder has analog temperature controls, single-gas input, includes a cart, includes the Nitrocell nitrogen generator, and requires assembly.

The 8003 is a fully capable analog nitrogen-generating welder for the budget-minded shop. Polyvance was the first to bring nitrogen welding technology to the automotive collision repair industry in 2006, and we have continued to be the innovator in nitrogen plastic welding since that time. Your nitrogen plastic welder will give you the ability to weld virtually any broken plastic material quickly and with great strength. Please watch this entire video to learn how to set up and use your new plastic welder.

Timestamps:

• Unboxing and Initial Setup (1:26)
• Safety First (7:39)
• Turning on the Welder for the First Time (8:25)
• Shutting Down the Welder (10:56)
• Doing a Basic Weld (11:22)
• Helpful Accessories (18:21)
• Troubleshooting (20:49)

View all our nitrogen plastic welders here: www.polyvance.com/Nitrogen-Welders-1/

Check out our training options here: www.polyvance.com/Training-2/ (3 hands-on options, 2 online options)

Watch our nitrogen plastic welding videos and our thermoset polyurethane repair videos.

Have a look at the Welding Cart Assembly Instructions and the 8003 Quick Start Guide

Always wear proper safety gear while working!

Let us know your thoughts on this video by leaving a comment on YouTube!
Click here: www.youtube.com/watch?v=9wu6W8h6L-U

Featured Products:

• 8003 Nitro-Fuzer® Nitrogen Plastic Welder (analog, single gas, cart assembly required, generator included)
• 6040 Whip Hose
• 2000 Flex Filler
• 6146 Bumper Pliers kit
• 6204 Hot Spot Plastic Staper
• Cutting Burrs and Bits
• 6061-1 Nitrogen Welder Cart-Generator Cover
• 6074 Accessory Shelf

Video Notes:

• English Closed Captions have been provided for this video. Click on the CC button to turn them on or off.
• The length of this video is in no way representative of the actual time required to perform a complete repair and therefore should not be used for estimating purposes.

Music Credits:

• "Wallpaper" Kevin MacLeod (incompetech.com)
  Licensed under Creative Commons: By Attribution 3.0 License
  http://creativecommons.org/licenses/by/3.0/

English Transcript:

This is the setup and use video for the 8003 Nitro-Fuzer® Welder. This welder has analog temperature controls, single-gas input, includes a cart, includes the Nitrocell nitrogen generator, and requires assembly.

Thank you for your purchase of the Polyvance 8003 Nitro-Fuzer® nitrogen plastic welder. This is a fully capable analog nitrogen-generating welder for the budget-minded shop. Polyvance was the first to bring nitrogen welding technology to the automotive collision repair industry in 2006, and we have continued to be the innovator in nitrogen plastic welding since that time. Your nitrogen plastic welder will give you the ability to weld virtually any broken plastic material quickly and with great strength. Please watch this entire video to learn how to set up and use your new plastic welder. This video includes the following sections: Unboxing and Initial Setup, Safety First, Turning on the Welder for the First Time, Doing a Basic Weld, Helpful Accessories, and Troubleshooting.

To keep the costs down on the 8003 Nitro-Fuzer®, we ship the welder, the cart, and the generator in three boxes. You will have to assemble the cart yourself. This video and the supplied assembly instructions will walk you through the process.

The smallest box contains the welder, which is fully assembled and ready to go. This box also contains the airless plastic welder and tips, power cord, accessories, and a selection of welding rod.

The larger, flat box contains the welder cart that we will assemble. Inside the box, you will find the assembly instructions and all of the welding cart components. You will need to have some tools to assemble the cart, like a Phillips-head screwdriver, a seven-sixteenths inch wrench, and a speed driver. The cart assembly will take about half an hour.

Once the cart box is unpacked, you'll see that you have a total of 18 different components. You should have one bag of nuts and bolts, the power strip, air manifold, and all the sheet metal parts. The one tricky part of putting the cart together is making sure the legs are put on the proper side. The legs are mirror images of each other. You can see that these two holes are flipped, so you want to make sure the holes point toward the front of the cart when you assemble it.

After assembling the cart, it's time to install the welder onto it. Put the welder up on the top shelf. Put one sheet metal screw through the shelf and line it up on the bottom of the welder, then screw it in by hand loosely until you have everything lined up. Put the second screw in, and make sure it also lines up with the hole in the bottom of the welder. Then use the speed driver to finish tightening up the screws.

Remove the nitrogen generator from the largest box and install it onto the cart by dropping it into place. Make sure the air and nitrogen fittings are facing toward the welder. Use the supplied strap to hold the generator in place on the cart.

Now that the welder and generator are secure, it's time to hook up the plumbing to the welder. First, connect a flexible green tube from the air manifold at the front of the cart to the inlet port on the nitrogen generator. The air goes into the outboard port marked “Air In”. Then from the “Nitrogen Out” port on the generator, run the tube through the welder shelf and into the fitting on the back of the welder.

To establish the electrical connection between the welder and the power strip, you'll just insert the end of the power cord into the back of the welder and plug the other end into the power strip.

If there is any masking tape on the nitrogen welder torch, remove it. Carefully attach the nitrogen welder hose to the welder by lining up the notches in each part. Do not push the connector in -- the pins are easily damaged. Use the threaded collar to pull the connector in.

Next, we will set up the airless plastic welder. The airless plastic welder is used for smoothing your nitrogen welds, and is essential for repairing urethane plastics. The nitrogen welder cannot be used to repair urethane. The airless welder comes with two welding tips: the flat, teardrop shaped tip is used for smoothing welds, and the tube welding tip with the hole that you feed rod through. You will use the tube tip and our urethane plastic welding rod to repair urethane bumpers. Since we will be using the flat tip more often, we will screw it into the airless welder. Plug the airless welder into the front of the welder.

Now we need to get set up for welding. Install your shop's quick disconnect plug into the air manifold on the front. The hole on the front is intended for a whip hose to supply air to your plastic grinding tools. Polyvance sells a ten-foot whip hose with an in-line blower as an accessory. Put the included tools, accessories, and welding rods in the tool bins at the top of the cart. Hook up your shop air line to the fitting. Make sure to use clean, dry, oil-free air, especially with the nitrogen membrane. If water or oil gets inside the system, it will ruin the membrane and other components, which will not be covered by the Polyvance warranty.

The Nitrocell nitrogen generator includes an air-oil separator to help ensure that the membrane receives clean, dry air. If you see any liquid in the bowl, drain it from the bottom. Keep an eye on the sight glass at the top of the filter; when it turns from green to red, you will need to replace the internal filter. If you have any doubts about the quality of your compressed air, use a filter-dryer at the wall where you plug in your welder.

Make sure your shop air is at least 100 psi. The purity of the nitrogen coming from the generator increases as the supply air pressure increases, and 100 psi is the minimum required to generate 97% pure nitrogen.

With the air line and nitrogen hooked up, you are now ready to use the welder. Please watch the rest of this video to learn how to use your welder for the first time.

Before you turn on your welder for the first time, please keep in mind the following safety precautions. First, use safety glasses whenever grinding or sanding plastic. Second, we'd recommend that you use mechanic's gloves to protect yourself against accidentally touching hot components. Finally, and most importantly, do NOT touch the metal barrels on either the nitrogen welder or the airless welder. They get VERY hot and can cause severe burns on contact. Be conscious of this hazard as you weld and try to prevent distractions from taking your mind off this point.

Your Polyvance welder has automatic low-flow heating element protection, but despite that, always get the nitrogen flowing through the torch before you turn on the heat. First, attach your shop's compressed air line to the air manifold at the front of the welder. Make sure your air is clean, dry, and free of oil. Oil and water in your compressed air will damage the welder's internal components. If in doubt, install a filter-dryer at the wall where you plug in your welder. When you have the air hooked up to your welder of at least 100 psi, you will automatically be flowing nitrogen out of the welder tip.

Turn the flow valve until the ball in the analog flow gauge floats at about 12 liters per minute. This is a good flow rate for your average bumper cover. If you are welding a very thin area, you can reduce the flow to about 10 liters per minute to prevent distortion of the plastic. If you are welding something thicker, like a heavy truck side panel, increase the flow to about 15 liters per minute to weld faster. With Polyvance's nitrogen plastic welders, you get full control of the welding process.

Plug in the power strip, and make sure it is on by looking for the lighted red switch. Turn the power on to the welder with the on-off switch on the back of the welder. You will notice the green "pressure safe" light glowing if there is sufficient airflow through the welder.

Adjust the temperature of the nitrogen side to match the plastic you're working with and the nitrogen flow you plan to use. For polypropylene welding with the standard flow setting of twelve liters per minute, the temperature should be set to 7. You will be able to feel the air start to get hotter immediately. Allow about five minutes for the element to warm up completely before use.

Turn on the airless plastic welder to help smooth out your plastic welds. For polypropylene, set the temperature at the "PP" setting on the dial. It will take about five minutes for the airless welder to get up to the proper temperature. While your welder is warming up, select the welding rod that matches the plastic you will be welding.

If everything seems to be functioning as described, you'll be ready to perform your first weld. Please watch the next section of this instructional video to see how to perform a basic nitrogen weld. Before that, though, let's take a look at how to properly shut down the welder. Simply turn off the main power switch on the back of the welder. Let the air continue to run for about five minutes to cool down the heating element. This will help to prolong the life of your heating element. Once the welder has cooled completely, disconnect the welder from the shop air supply and unplug the welder.

If you've never done a nitrogen plastic weld before, don't be afraid to try it out. For safety's sake, be aware that the barrels of both heating elements get extremely hot and may cause burns. Wear eye protection and temperature-resistant gloves for your safety.

Get a bumper out of your scrap pile. Clean both front and back with soap and water first and let it dry. Look on the backside of the part for the plastic ID symbol. These are usually two or three-letter designations molded into the backside. The letters are often shown between two arrows pointing toward them. Here, you can see the bumper says "PP-EPM", which means the plastic is a mixture of polypropylene and synthetic rubber. Whenever you see the "PP" on the part, use the R02 polypropylene welding rod. Your welder comes with a selection of natural polypropylene rod in five different profiles. For fusion welding, always use the welding rod that matches the substrate. Do not use FiberFlex welding rod with the nitrogen welder. This is a specialty welding rod for use with the airless plastic welder, which you can learn to use later. At this point, let's concentrate on a simple nitrogen weld on a polypropylene bumper.

To practice a full bumper repair, cut the bumper at the bottom edge for a couple of inches with a pair of tin snips. Do your weld on the backside first with the R02-04 welding rod. Grind a shallow v-groove into the plastic on the backside with a die grinder about the width of the welding rod. In order to perform a good fusion weld, you have to expose the raw plastic, so grinding off any paint overspray is essential. To strengthen the repair, grind along the edge for about an inch on either side of the split so you can weld a reinforcing tee. Finally, apply aluminum tape to the outer surface of the tear to align the damage.

Normally you'll weld from the inside toward the edge. Starting here, hold the welding rod close to the bumper and preheat the end of the rod and the bumper using the hot nitrogen gas. The bumper will start to look glossy and the end of the rod will start to melt. At this point, apply a slight downward pressure on the rod while continuing to focus the hot nitrogen gas at about a 45-degree angle where the two materials come together. The key to making a strong nitrogen weld is to melt both plastics at the same time. Note that the welding rod is held perpendicular to the surface while the welder torch is held very close to where the rod meets the bumper. The rod will roll down onto the bumper naturally as it gets to the right temperature as you hold a slight downward pressure on the rod, fusing the two plastics together as you make your pass.

When you get to the end, cut the welding rod by heating on the top and gently pulling straight off or down. Allow the weld to cool for a bit, then reinforce the repair by welding a tee along the edge using the same technique. Weld along the edge for about one inch on either side of the tear. Again, cut off the welding rod when you reach the end by heating the top and pulling straight or using the torch's nozzle to cut the ribbon.

While the weld is hot, you can use the airless welder to smooth the weld if needed. Don't flatten the weld completely, just dress the edges and smooth it.

Let the weld on the backside cool completely before you do anything on the frontside. Cooling can be accelerated by blowing compressed air or applying a wet towel on the weld. Once it's cool, flip the bumper over and peel the aluminum tape off the frontside. On the front, use one of the narrower welding rods to keep the repair area as small as possible. For this repair, let's use the R02-07 narrow ribbon. Grind a v-groove about the width of the welding rod halfway through the bumper, or until you see the welding rod from the other side become exposed. An optional step would be to feather the paint back from the v-groove with some sandpaper. Again, it's important to weld only to raw plastic, not paint.

As before, direct the heat from the nitrogen welder at about a 45-degree angle to heat both the bumper and the end of the welding rod. After the plastics begin to melt, apply a slight downward pressure on the rod to begin your weld. Keep the welder's heat focused where the rod and bumper come together, making sure to melt both plastics at the same time as you make your pass. If the v-groove is not filled with welding rod, make another welding pass until the v-groove is filled.

When that is done, use the airless welder to smooth the top of the weld. Lay the welder on the surface and pre-heat the welding rod with the nitrogen at the same time. Let the weld cool to room temperature before sanding or testing its strength. This can be accelerated by blowing it with compressed air or applying cold water.

Test the strength of your weld before you invest any time in the refinishing process. As you can see, this weld will be more than sufficient to carry this bumper to its next accident. Once you're satisfied with the strength, sand the weld flush by knocking it down with a 50 grit disc in an angle grinder, then using 80 grit in a DA sander. Normally you'll sand the repair slightly flush then apply a flexible filler to finish. Polyvance's 2000 Flex Filler is an excellent choice, for its epoxy formulation gives it great flexibility and it is easy to sand and finish.

Congratulations on making your first plastic weld! Your welder comes with a QR code sheet which gives you instant access to Polyvance's complete training video library. Please review some of the other welding techniques on the Polyvance website or on the Polyvance smartphone app. Polyvance has the industry's most extensive plastic repair and refinishing training resources. If you are interested in taking one of Polyvance's live, hands-on I-CAR Training Alliance courses, contact our training department by going to our website or calling our toll-free number.

Although your Polyvance plastic welder is the most fully featured in the industry, Polyvance offers other accessories to help make plastic repair easier, faster, and more profitable. Check out the "Accessories" brochure that came with your welder or go to the Polyvance website for the current offerings.

One of the most popular accessories is the 6146 Bumper Pliers kit, which helps make repairs to the rectangular mounting slot tabs much easier. The metal die inserted into the hole prevents melted welding rod from obscuring the hole, making the process easier and more accurate. After the plastic cools, you'll simply have to finish the top and the edge for a complete repair. A plastic stapler from Polyvance is a helpful complement to the plastic welder. Hot staples are great for holding headlight tabs in position or for tacking long tears together that are too much for the aluminum tape to hold by itself.

Polyvance offers a wide range of cutting burrs for both air die grinders and for electric Dremel tools. These burrs are designed for cutting plastic quickly so you can start welding as soon as possible. The carbide cutting burrs make quick work of your v-grooves, and the drum sanders for your Dremel tool are great for preparing and finishing mounting holes and headlight tabs. A custom-fit dust cover from Polyvance will keep your nitrogen welder protected when you're not using it. The optional 6074 Accessory Shelf mounts to the top of your welder and provides lots of extra space to hold tools and accessories. It folds away when not in use for ease of storage.

Polyvance also makes refinishing materials like plastic cleaners, flexible fillers, adhesion promoters, high-build waterborne primer-surfacers, and specialty paints like our Flextex VT texture coating. Go to the Polyvance website to learn more about all the products that will make your plastic repair process easier and faster.

Polyvance is the only company in the industry focused exclusively on plastic repair and refinishing. We have the experience, products, and training resources to help you make better and more profitable plastic repairs. Thank you for allowing Polyvance to help you.

Rigorous quality checks are performed at the Polyvance factory to ensure the welders are fully functional and complete before they are packaged for shipping. However, if there is an unforeseen problem, we've included a troubleshooting section in the welder's Quick Start Guide to help you diagnose the issue.

If your welder won't turn on, check that the power supply you have the welder plugged into is putting out 120 volts. Make sure your power strip is on. Make sure that all the cords are plugged in all the way. Finally, check the fuse on the back of the welder. Pop it out of the fuse holder and check the continuity across the fuse with an ohmmeter. If the fuse is blown, you will also need to identify the root cause. Call Polyvance technical support for assistance.

If your nitrogen welder is not getting hot enough, check that your nitrogen flow is about 12 liters per minute and that the temperature is set at about 7 or 8. At this setting, it should get hot enough to gloss over polypropylene in about three to five seconds. Normally if the welder is not getting hot enough, it's because the flow is set too high and the temperature hasn’t been increased accordingly.

If the nitrogen welder doesn't get hot at all, and the green light is glowing, it's most likely you have a burned-out heating element. Unplug the welder, then remove the heating element from the handle. Check the resistance of the element across the two pins -- it should be about 26 ohms. If your multimeter shows open circuit, the element is burned out and needs to be replaced. If the element shows 26 ohms and still doesn't get hot, call Polyvance for technical support.

If your airless welder does not get hot, check the resistance of the heating element using an ohmmeter across the two pins on the plug. It should read about 53 ohms. Again, if it reads open circuit, the ceramic heating core inside the airless element will need to be replaced.

For any other problems, call Polyvance at 800-633-3047 between 7 AM and 4 PM Central time for immediate help. Since 1981, Polyvance has been committed to providing the best customer service and technical support possible with a live human being answering the phone to give you immediate assistance.

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