Repairing a Smooth Headlight Tab Using the Nitrogen Plastic Welder

Many front-end collisions result in broken headlight tabs like this. Today’s headlights often feature LED bulbs, moveable elements, and sensors which greatly increase the complexity and cost of the headlight. Repairing damaged headlights can be a profitable and ecological opportunity. This instructional video shows how to repair this smooth, visible headlight tab using Polyvance’s nitrogen plastic welding system.
This particular tab is smooth on top, making it relatively easy to refinish. If the tab has gussets or ridges on top, Polyvance’s 6225 Tab Magic molding putty can make it easier to repair and refinish. Check out Polyvance’s PR-03 Headlight Tab Repair Course for even more strategies on how to repair different types of headlight tabs.
View this video on our website for products used and more information:
www.polyvance....
⚠️ Important ⚠️
- Always wear proper safety gear while working!
- 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.
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🎵 Music Credits:
"Sage" by Slenderbeats
From the RUclips Audio Library

[@thehonestman26]

I have a different plastic welding setup, but you did a good job here. Looks really nice.

[@polyvance]

Thanks!

[@Sam-to1zg]

Blown up my mind with quality of repair and video.

[@geoffreycartmill7717]

Excellent repair job and excellent video as always

[@froglobster]

That was very interesting thanks for the demo!

[@polyvance]

Thanks for watching!

[@rolandcantu8752]

Do any body do it here in san Antonio tx.if yes please giue your information so I could call.thankyou

[@csurams84]

This is amazing 👍🏾

[@polyvance]

Thanks for watching!

[@Guspech750]

Awesome video

[@polyvance]

Thank you!

[@radonvon3120]

How much is all of this stuff to do this job

[@user-oo9ey4ft9d]

Good
جيد جدا

[@DanielMartinez-tg6ix]

What is a ballpark estimate of touch time for this repair? Not counting cool down times or flash times of some steps that were used? For this particular headlamp, what would you guess was the actual repair time spent on it? I am a high school auto body teacher and am talking about repair times with my classes, this information would be great to add to explanation. Also, I was able to purchase one of the polyvance nitrogen welders with table this past school year.

[@scottb7600]

It varies depending on the complexity of the tab. Waffle tabs take longer than flat tabs and ribbed tabs fall somewhere in between. I would say touch time can be ballparked to somewhere around 1 hr average to get it looking OEM. However, bottom tabs can be done MUCH quicker because you don't need to make look pretty, just functional; probably 15 minutes for those...most of that time is spent doing prep work.

[@JoseDiaz-er4ww]

Looks like the repair will cost more than a new headlight? hahahahathe final job was amazing.

[@polyvance]

Newer headlights can be surprisingly expensive! A shop that can repair headlight tabs can pay off the machine in just a few jobs!

[@andreybalanchuk8387]

What temperature are you running with your air welder? Seem pretty hot welding rod like this, way over 160C (PP melt point).

[@scottb7600]

Yes, the Nitrogen temp is well over the melt point of PP. It has to be in order to transfer enough heat to the rod to melt it....just like welding with an oxyacetylene torch is way over the melt temp of steel. The nitrogen temp is roughly 900°F (482°C) before it exits the heater but in that 1/4 in between the nozzle and the substrate, the temp drops significantly.

[@andreybalanchuk8387]

@@scottb7600 Thanks Scott, useful information! Couldn't find any Polyvance video wherer whole tab is welded back (base is broken off at the edge of headlight), is there any? It requires heating from both sides before sticking it back, looking for a safe way to do that.

[@polyvance]

No, we don't currently have a video like that. If you want to send some pictures of your damage to [e-mail], someone can get back to you with suggestions.

[@1drwnd.porsche]

This is great but not for the regular DIY guy considering the amount of stuff one has to purchase for a 1 maybe 2 time fix.

[@scottb7600]

The video is geared more to the professional, but if your headlight costs $2000 (and there are a lot out there that do) buying all the tools to make the repair would be more than worth it. Plus, you'd have the tools to repair a lot of other things made of plastic.

[@nickdavis6294]

I dont have any of those tools. Prolly cheaper if i just buy another headlight

[@balsonnaoshekpam6240]

I need for my car

[@wilsonparana2427]

👏👏👏👏👏👏👏👏👏👏👏👍👍👍👍👍👍👍👍👍👍👏👏👏👏👏👏👏👏