Volkswagen ID.3: General information, Body. Welding plastic attachments

Volkswagen ID.3 (E11, E12) 2020-2024 Service Manual / Body / General information – body / General information, Body. Welding plastic attachments

Welding crack up to length of 100 mm
Welding tab

Welding crack up to length of 100 mm

– → Rep. gr.52; Repair deformations.

Important

● Both sides of the crack must face each other in relieved condition.

– → Rep. gr.52; Preparing plastic repair.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

Painted plastic attachments

– Sand repair area with a commercially available orbital sander -A- and P120 grit sandpaper.

– Blow out sanding residues.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

All vehicles (continued)

If the plastic attachment does not have a small thickness:

– Use a commercially available conical milling cutter -B- to mill a V-shaped bevel on the inside and outside along the crack -arrow-.

– Blow out milling residues.

– Align crack -arrow- flush.

Continued

– Insert wedge-shaped welding nozzle -B- into hot air blower -A-.

– Use wedge-shaped welding nozzle -B- at welding temperature to spot weld plastic attachment along crack -arrow-.

Important

● The contact line of the wedge-shaped welding nozzle -B- must be guided parallel to the surface.

● If the contact line of the wedge-shaped welding nozzle -B- is not guided parallel to the surface, material will be removed.

Note

The first welding pass is carried out without applying material to create a connecting line between the edges of the crack. The connecting line is the basis for the material application.

– Use a commercially available knife -A- to bevel end of welding rod -1-.

– Make sure that welding rod -1- is clean and in good condition.

– Insert adapter nozzle for welding -B- into hot air blower -A-.

– Place welding rod -1- with bevelled side at end of crack.

– Move hot air blower -A- in a wagging motion.

– Use hot air blower -A- to heat up welding rod -1- an body attachment until welding rod -1- and body attachment become soft at the same time.

– Push welding rod -1- into area of crack to apply material.

Important

● The pressure on the welding rod -1- must be sufficient such that the welding rod -1- can bond with the body attachment. The welding rod -1- must not deform or break the V-shaped bevel.

– Guide welding rod -1- vertically along the path of the crack.

Important

● Welding rod -1- must be held at an angle of 80º to 90º to the surface.

– Move hot air blower -A- along the crack.

– Select welding speed so that:

♦ the material does not decompose or deform.

♦ the welding rod -1- bonds with the body attachment.

After the crack has been welded:

– Allow body attachment to cool down.

– Separate excess welding rod.

Continued

– Repeat the procedure on the other side of the body attachment.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

– Use a commercially available conical milling cutter -B- to remove excess material from weld seam -arrow-.

– Blow out sanding residues.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

– Sand repair area with a commercially available orbital sander -A- and P120 grit sandpaper.

– Blow out sanding residues.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

– Apply primer -A- → Rep. gr.52; Processing instructions – original products.

– Apply 2 cm of adhesive bead -arrow- on test piece.

– Make sure that both components of the plastic adhesive -A- are completely mixed.

– Apply plastic adhesive -A- → Rep. gr.52; Processing instructions – original products.

– Use a commercially available spatula to spread adhesive bead -arrow-.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

– Sand repair area with a commercially available orbital sander -A- and P150 grit sandpaper.

– Blow out sanding residues.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

Welding tab

– → Rep. gr.52; Preparing plastic repairs.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

– Use a commercially available conical milling cutter -B- to mill a V-shaped bevel on the inside and outside along the crack -1-.

– Blow out milling residues.

– Clean repair area with plastic cleaner → Rep. gr.52; Processing instructions – original products.

– Insert wedge-shaped welding nozzle -B- into hot air blower -A-.

– Align tab -1- flush.

– Use wedge-shaped welding nozzle -B- and hot air blower -A- at welding temperature to spot weld tab along its entire length.

Important

● The contact line of the wedge-shaped welding nozzle -B- must be guided parallel to the surface.

● If the contact line of the wedge-shaped welding nozzle -B- is not guided parallel to the surface, material will be removed.

Note

The first welding pass is carried out without applying material to create a connecting line between the edges. The connecting line is the basis for the material application.

– Use a commercially available knife -A- to bevel end of welding rod -1-.

– Make sure that welding rod -1- is clean and in good condition.

– Insert adapter nozzle for welding -B- into hot air blower -A-.

– Place welding rod -1- with bevelled side.

– Move hot air blower -A- in a wagging motion.

– Use hot air blower -A- to heat up welding rod -1- and tab -2- until welding rod -1- and tab -2- become soft at the same time.

– Push welding rod -1- into area of crack to apply material.

Important

● The pressure on the welding rod -1- must be sufficient such that the welding rod -1- can bond with the body attachment. The welding rod -1- must not deform or break the V-shaped bevel.