How to repair a hole in a plastic bumper

Updated July 20, 2017

When you get into an accident and there's a hole in one of the bumpers on your vehicle, it is not always necessary to purchase a replacement bumper. As long as the bumper is in decent overall condition, the hole can be fixed and refinished. Repairing the bumper, as opposed to purchasing a new one, can save you hundreds of dollars in labour and installation costs. With the proper tools and instructions, the process can be completed in a few hours.

Grind out the holes on the bumper using a mini grinder and 36-grit sandpaper. Continue by roughing up the area around the holes with 80-grit sandpaper. Roughing up the area makes it easier for the adhesives to set. Use an alcohol-based cleaner on the entire area.

Apply plastic adhesive promoter to the area around the holes and allow it to dry for 15 minutes. Apply pieces of mesh over the holes to help the adhesive stick to the plastic on the bumper. With the mesh in place, apply a Kent epoxy-based adhesive putty. Apply enough of the adhesive putty to cover and fill in the mesh and the grinded area. Repeat the same steps for the front side of the bumper.

Sand the front of the bumper by starting with 80-grit sandpaper and gradually working your way up until you reach 180 grit over the course of five minutes. Apply primer to the damaged area using a sandblaster and 320-grit sandpaper. Work the primer into the area and gradually work up to 500 grit over the course of approximately five minutes. Once this process is completed, the hole on the bumper should be repaired and smooth to the touch.

Things You'll Need

  • Mini grinder
  • Sandblaster
  • 36- , 80-, 180-, 320 and 500-grit sandpaper
  • Alcohol-based cleaner
  • Adhesive plastic promoter
  • Mesh
  • Kent epoxy-based adhesive
  • Auto primer
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