Poly Welding

[flootapooch]

G'day everyone,

just wondering if anyone has put themselves on a poly welding course? I haven't even done metal welding, so I might be getting a bit ambitious.

Thing is I bought my boat second hand and there are few mods the previous owner made and removed before selling, leaving some holes behind. One of these holes is a fair size (about 2 inches diameter) on the gunwhale and he filled it in with solastic or something. Needless to say it's not a realy good job and it's right where one of the screws for the bimini goes. There are also some other orphaned screw holes and a small crack in the casting deck that needs sorting out.

I know I can get it done (should be loads of places in Brisvegas) but just thought it might be good to know how myself - and my old man's got a poly kayak which could do with a bit of work...

Anyone got any experience here?

Cheers,
Pooch.

[Dave]

I have no idea about poly welding as a trade? If it is a trade in itself.

With the amount of poly 'things' around now a days, it would be a good little business on the side of your normal job.

The splash chines are becoming popular and there may be some business in that alone.

I have side pockets in my boat which are welded in construction and then welded into place.

There are also poly material live bait tanks some guys have on the rear of their boat.

The current seat pods in most of the poly boats are too small to be useful. Making a larger size may be a side line as well.

The options are endless.

Have you made any enquires about the course? What it comprises of, length etc?

I didnt answer your question here but maybe given you a few ideas should you pursue the idea and are looking to recoup some of your costs. ;)

[flootapooch]

Nice thought Dave, but I barely get time to mow my lawn and go for a fish, let alone getting another job. I thought there might be an adult education style course - one night a week for 6 weeks style thing where they give you the basics of poly welding. It may not exist of course...

Cheers,
Pooch.

[Doug]

I think there might be some considerable expense in buying the welders surely?

[Pirate Pete]

I have heard of prices from $350 up for the small hand held ones like what the carpel layers use to weld vinal floors.

[Doug]

vinyl, Pete. Go and apologise to Miss Jane.

[BarryJ]

I have a dedicated plastic welding nozzle ($25) for my hot air gun (~$125).:) Just need to learn how to use it.(whistle)

[Doug]

You have a hot air gun? You told me you weren't married...

[BarryJ]

But I WAS married...................(whistle)

[Doug]

So now you're just gun-shy?

[BarryJ]

Or that I have finally come to my senses.........................(whistle)

[Pirate Pete]

I have a dedicated plastic welding nozzle ($25) for my hot air gun (~$125).:) Just need to learn how to use it.(whistle)

Where did you get it Barry??? & Do you have a pic??

[BarryJ]

No pics, Pete (will take a couple over the weekend); it's just a standard Bosch model plus a full set of attachments (four nozzles from memory) I bought from Nubco.

[Threadie]

Ebay has poly "welders" for sale if you are interested.
For under $200 you can get what you need, just search plastic welder

[Dave]

Interesting. I did a search and then realised I dont even know what a plastic welder looks like.

Is this it?

http://cgi.ebay.com.au/PLASTIC-WELDER-HOT-AIR-HEAT-PISTOL-REPAIR-NEW_W0QQitemZ330387806096QQcmdZViewItemQQptZAU_Pow er_Tools?hash=item4ceca5d790

If so I would have to see a demo to work out how to use it.

Where's Bones and Geobec to tell us?

[BarryJ]

Yeah, basically just a hot air gun with a special nozzle to take the welding rod. Will post pics of my unit tomorrow. However, I don't know what an industrial plastic welder would use (that is if it is any different).

[chin]

I guess you could buy one and practice on your wheely bin.
Bones and Geobec would know what sort of gear a pro uses, because they were breathing down the neck of the poor bloke who did their spray chines while he was working for them. (whistle)

[Dave]

You could imagine the poor guy with excitable george around... he is excitable enough on the phone...lol

[BarryJ]

Yeah, basically just a hot air gun with a special nozzle to take the welding rod. Will post pics of my unit tomorrow. However, I don't know what an industrial plastic welder would use (that is if it is any different).
Hot Air Gun (Makita, not Bosch as I previously mentioned) with three (not four) nozzles:

http://i10.photobucket.com/albums/a106/BarryJ49/other/Hot_Air_Gun0001800x600.jpg

End of grip showing temperature control. The end of the grip is flat so that you can sit the gun on it and have the hot air blowing upwards:

http://i10.photobucket.com/albums/a106/BarryJ49/other/Hot_Air_Gun0006800x600.jpg

[BarryJ]

Nozzle close-ups

Wide Nozzle (I use this one for applying stickers to the hull and tidying up any scrapes etc):

http://i10.photobucket.com/albums/a106/BarryJ49/other/Hot_Air_Gun0002800x600.jpg

Plastic welding nozzle:

http://i10.photobucket.com/albums/a106/BarryJ49/other/Hot_Air_Gun0004800x600.jpg


Plastic welding nozzle rotated 90deg (you can just see the hole in the tip for the welding rod to pass through):

http://i10.photobucket.com/albums/a106/BarryJ49/other/Hot_Air_Gun0005800x600.jpg

Third nozzle just directs air flow horizontally when gun is sitting on the end of the hand grip:

http://i10.photobucket.com/albums/a106/BarryJ49/other/Hot_Air_Gun0003800x600.jpg

Edit: I'm a fisherman, not a photographer!!!!!!!!!!!!!!!!!

[Doug]

Help, I'm going blind - all Barry's pix are blurred.....

[BarryJ]

Doug, stop doing it before you go completely blind!!!!!!!!!!!!!!!!!!!!!!!! (whistle) :D

[Doug]

Too late. I'm training the dogs, just need an old pram handle to attach to them.

[BarryJ]

Keep an eye out on garbage collection nights after Xmas. There may well be some old doll's prams being discarded. (Console)

[cam1]

Gday guys just been looking on u tube for polywelding techniques and tips and came across Tap Plastics Glue like an epoxy mix.looks pretty strong for small repiars and might even be able to help in setting up a larger project for the final welds?

http://www.youtube.com/watch?v=h-9yhanz5DE

couldnt find out about it being distributed in aus or not but im sure that there would be something similiar

[Giffo]

Barry ,looks like parts of your boat stuck to the end of the 2 centre pictured nozzles.

[BarryJ]

The plastic welding rod got a bit hot at one stage. :eek: (whistle)

[BigFella]

Good photos Barry, Ill have to remember to take close ups next time I take a shot of my tool,,,,s!:rolleyes:
Hey out of the gutter you mob! Thats Doug's hide out!!(alco)

Now back onto topic, I purchased one off flebay and it works quite well for the smaller repair jobs!
For larger work such as welding in pods, consoles and the like you will need to spend upwards of $1,500 - $2,500 for a dedicated self feeding poly welder. And thats only the starting price, an industrial poly welder can cost you $5,000.00!
But for the smaller jobs and repairs the flebay specials are fine. I do repairs on Polycrafts and other things plastic with good results.

Give it a shot, nothing to lose really at those prices!(whistle)

Cheers.

[Mark]

Hey Pooch
I bought a plastic welder from EBay it has a nozzle attachment to a small tube to create a small area which is good for welding. Then a couple of weeks ago I was 4WDing out at Binnies Rd and crushed a front flare on a big tree root. With NO nozzle it heated a large area to re-shape the flare. On the triumph USA owners web site, Some owners got together and made a DVD which covers all the questions people had about Plastic boats. This could be a great idea for polyboats to look into. The DVD covered things like

How to apply stickers to Roplene
How to repair scratches or gouges by welding Roplene
Buffing Roplene to shine (if you want to)
How to replace screws with Roplene powder
How to use Rule Elastomeric for sealing
Where to install a transducer
Lacing a t-top
What to look for in trailer maintenance
Prop removal and checking for debris
Consider installing an on-board battery charger system
Techniques for mounting down riggers
Cleaning the bilge pump
Installing Transom drains
Lower unit maintenance
And more

I purchased the DVD & it gave me the confidence to weld my boat, without fear of screwing it up. Whenever I cut out speaker holes or access covers, I always keep the cutouts as they are perfect to use for filling & welding. ( perfect match for colour & plastic type) When filling holes, I drill hole to a larger size first to remove and dirt or grease that will mess with the colour when welding, & reduces strength of weld. I have a white boat & the dirt really stands out if not removed first. I got a roller with my plastic welder, so after filling in hole(welds like twisting in bubblegum) I use the roller to flatten out weld & save alot of sanding later. With my cutout pieces, I practiced first on them. Drilled holes & welded them up. Best FREE course you could ever do.

Cheers
Mark

[flootapooch]

Outstanding. Thanks Mark. That sounds exactly what I am after. Do you remember if the polywelder you bought was from a dealer on Ebay or from an individual? If it was a dealer and you can remember their name, I would really like to know so I can get one. I would also be interested to know if it was just a heat gun with some attachments or if it was a bit more sophisticated.

I'll look in to getting one of those DVD's too. Sounds great.

Thanks again and thanks to everyone else who has contibuted to this thread.

Cheers,
Pooch.

[Mark]

Hey Pooch,
http://cgi.ebay.com.au/PLASTIC-WELDER-FOR-SMASH-REPAIRS-VINYL-SIGNS-BANNERS_W0QQitemZ250555260529QQcmdZViewItemQQptZAU _Car_Parts_Accessories?hash=item3a5641de71
http://i557.photobucket.com/albums/ss17/kaikai888/PB190018.jpg

This is very similar to what I got. So many to choose from on EBay so take your pick. It has an adjustable temp dial on the back & you HAVE to make sure you turn it down
to lowest setting (Coldest) and let it run for a while before you turn it off. if you get a kit with a speed feeder nozzle, like this one

http://amonstar.com/shop/images/speednozzle/a1.jpg
Speed Welding Nozzle can be bought separately

it allows you to slowly feed a strip of plastic as you move along the job. The near vertical tube is for the plastic strip & the angled tube slides onto small nozzle attachment
for the hot air. The plastic strip gets pre heated as it slides down the tube. It all happens alot slower than you would think. I have NEVER melted plastic to liquid burning mess
like I thought you would LOL, infact I have never seen it even close to a liquid. To me it seemed more like playing with soft bubblegum. The gun can also be used for heatshrink
& Marine electrical connectors with resin in them, Removing stickers, and warming up frozen hand in places like Tasmania laugh1

As far as the DVD goes, you can find it at http://www.tacklemonkey.com/Maintenance_Modifications_for_Triumph_Boat_Owners_ p246.html
Like I said previously, I found it worth every cent to have a step by step video guide to all those question about plastic boats. Hope you enjoy it too.

Cheers
Mark

[flootapooch]

Superb. Thanks again. I have spoken to Maureen at Polycraft (what a nice lady) and she has been really helpful too.

I guess there are other forums for tinnie owners and glass boat owners, but at the risk of sounding a bit gushy, the poly boat world has a lot of people who are ready to jump in and help out.

Which reminds me, time to get the wallet out for Jamie.... will do that today.

Cheers,
Pooch.