Repairing Blow-Molded Jeep Bumpers

In 2007, Jeep won an award from Plastics Technology Magazine for its groundbreaking use of blow-molding on Jeep Wrangler bumpers. This process is similar to the process used to make a soda bottle. Though innovative, blow-molded bumpers are thought by some to be impossible to repair, due to the fact that dents cannot be reached from the back. However, we have a repair technique that can remove the dents, eliminating the need to spend a small fortune on brand new Jeep Wrangler bumpers.

Chapters:
Intro: 0:00
Overview: 0:11
Marking and cutting a square: 0:37
Heating: 1:10
Push the dent out: 1:36
Sand: 2:11
Heat, push, sand, repeat: 2:21
Sand with 180 grit: 2:45
Apply adhesion promoter: 3:02
Prime: 3:11
Place the plug: 3:24
Prep for welding: 3:41
Weld the plug: 4:02
Finished look: 4:22

Look below for links to some of the products from the video.

⚠️ 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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[brunettem]

I fallowed your steps and repaired my Jeep bumper but without sanding and paint finish.. thanks 🙏🏼 for the tutorial

[martinpoliti]

I left the bumper on and it was a 10 minute repair job. I have two tips, only cut 3 sides to make a flap, and also instead of cleaning up all the attached plastic shreds to the edges of cuts, once repairing the dent, I used the heat gun and a screwdriver to melt/mend them back into the cuts for an easy seal. No glue required!

[herbertallen]

Watched your video and decided that I didn’t want to cut or drill any holes in my bumper. I found that my bumper already had four small drain holes in the bottom of it. I blocked all but one open hole and used an air compressor and a heat gun to inflate the bumper while applying a little heat to the dented area.  The dent popped right out as the bumper inflated. After that I used the heat gun to smooth out most of the creases that were left after restoring the bumper to its original shape.

[michaelwatchorn]

Looks better than factory! Great job!!

[joazm]

I used to repair bumper plastic... but this tool is perfect .

[johnqps]

Whoah, whoah, whoah there, Hoss. You were done halfway through step 3. This is a Jeep not a show car. ;-)

[Erik-gkwi]

i think I'd just buy a new bumper. probably less expensive than buying all that shit i don't own or have space for.

[tinybetron]

The back bumper is a sealed unit. It has two weep holes in the bottom one on each side. Put a self tapping screw in one, the other tap in a basic quick connect male fitting from your aicompressor. Set your pressure as high as it can go and connect an your air hose unpressurized at this time. Heat the area like in this video except once it is heated go to your compressor and give it a full shot of air. You will hear the dent pop out that sounds like a tire rim when mounted. The shut off the air and remove the selftapper and quick conect.Did this on mine and forget cutting holes and using push stick. It went back into original condition.

[bldallas]

Thanks for posting, but way more complicated than I’d

[bobgil]

I am impressed but as others shared it is cheaper and less labor intensive to buy a non OEM bumper replacement for around $90 and free shipping.

[peterdecton]

supreb job mate!!! but these bumpers can be got on forum for almost close to free... really good video though

[JEL]

I did this repair, but instead of cutting out such a large access hole, I drilled a 1" hole and used an old broom stick head to push out the dent. I plugged the hole with a rubber grommet which I had purchased earlier from an auto parts store. I didn't do any sanding, finishing was done with a high quality bumper paint. The rubber grommet gave the job a finished look. Like the gentleman said in this video, BE VERY CAREFUL WITH THE HEAT GUN, THESE BUMPERS MELT QUICKLY. My repair was done without removing the bumper, clearance was achieved by simply turning hard right or left depending on which side is dented....

[wutisay]

Easier, cheaper, and better result is to buy a non-OEM bumper cover. Good ones are available for under $90 with free shipping.

[colton]

Once a ram with a brush guard backed up and caused this exact dent to my dads old jeep. He just kicked it and the dent disappeared.

[cs]

Oh great. I was prepared to hit it with the blow dryer-woodscrew-JDWeld tactic, then I see this....Sometimes true craftsmanship is a bummer.

[pjreed]

That bumper is textured does this not matter that the sides do not match?

[Vincent-gtgx]

Just getting all the tools will cost me a lot of money! I would buy a used one from the auto wreckers.

[mako]

What a hevy rock music to repair a bumper

[larrygood]

You can buy the plastic replacement bumper cover for $67.00, also if you cut out that section from the back, you are compromising the integrity and original design of the bumper, the next time it takes an impact at that corner, it could easily fold over and make contact with the tire.

[RHopper]

By the time you add up materials and man hours, it's cheaper to buy a bumper.