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A 355nation How To presented by
ndb86

Project Name
Fix cracked bumper fascia

Project Description
How to fix a cracked plastic fascia

Skill Level
Moderate

Project Vehicle
Make: Chevrolet
Model: Colorado
Year: 2007
Engine: 3.7L
Power windows: No
Sun Roof: No

Tools Needed
Dremel or other rotatory tool
15mm socket
3-4inch extention(optional)
PLASTIC JB weld

PLASTIC primer spray can
Truck bed liner spray can

Project Time
2 hours work time a few days for drying time

Project Cost
Plastic JB weld ~$10
PLASTIC primer ~$10
Truck bed liner ~$10

Total cost ~$30


LONG story short I just barely hit a deer the other day. It cracked the bumper fascia and knocked my fog light off. So instead of buying a new one I decided to fix it.




Remove the grill and you'll see four (4) 15mm bolts underneath it. Remove these bolts. You may need an extention to get to the bottom two.

Under the truck on either side you'll see two (2) more 15mm bolts on either side in front of the wheel. Remove these as well.

Take the entire bumper off.

Flip it over. There will be several clips holding the metal to the plastic. Remove them. In the front there will be five (5) tabs that need to be squeezed with pliers and pushed though.

Now that you have the cover off I recommend putting the metal bumper back on as it will be a few days before the paint is dry enough to reassemble and local laws may require a bumper. This step is optional.

Without the cover it looks like this:


Next clean the plastic with a degreaser of your choice. I used Spray Nine.

Try to get the crack lined up as good close as possible. Use duct tape or similar on the OUTSIDE to hold it in place. Turn it over and use the dremel to cut a notch where the crack is so there is more for the JB weld to hold into.

Follow directions on the JB weld package. cut a chunk off and knead it until it is uniform in colour. Then press it very firmly into the crack and around it. It takes about 30 minutes to setup. Once cured remove duct tape from the front side, notch the crack again and apply JB weld.

Once cured (about 30 minutes) sand smooth with 120 grit sandpaper. Once smooth and flush with the plastic

It will look something like this:


Next clean it again with degreaser of your choice and let dry completely.

Set up your painting area and prime it.



I did 3 coats of primer. The primer I used allowed me to spray my top coat within 1 hour, others may specify longer. Read the label and do not apply top coat too soon. Some take 24 hours or more to cure.

Once primer is cured spray with bed liner. I did about 6 coats. 3 is probably good enough.


I had a couple of runs so I let it cure for 24 hours, then sanded them down with 320grit paper and resprayed those areas. You can avoid this by A)not doing it in a dark garage where you can't see what you're doing and B) spraying multiple thin coats.

Once it is cured as per directions on the can (24 hours for me) reassemble the opposite of disassembly.

Stand back and admire your work!



 

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http://parts.nalleygmc.com/showAssembly.aspx?ukey_product=2882313&ukey_assembly=436433

Item Number: 010
Part Number: 15811512
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(BLACK). Required: 01
For: ST1 CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(41U),(EXC FRT FOG LP(T96),CHEVY XTREME PKG(V4A) (2006-2007) (2006 - 2007).
For: ST1 CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(41U),(EXC INTERIM CONTROL CHANGE:REFER TO VEH OPT LABEL FOR VERIFICATION(CNV),FRT FOG LP(T96) (2008-2008) (2008 - 2008). Cost: $142.12

Item Number:010
Part Number: 15920029
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(BLUE). Required: 01
For: S1 FRT FOG LP(T96),CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(20U),(EXC CHEVY XTREME PKG(V4A) (2007-2007) (2007 - 2007).
For: ST1 FRT FOG LP(T96),CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(20U),(EXC INTERIM CONTROL CHANGE:REFER TO VEH OPT LABEL FOR VERIFICATION(CNV),SPORTS EQUIP SALES PKG(PFL) (2008-2008) (2008 - 2008).
For: ST1 SPORT PERFORMANCE PKG(B4U),FRT FOG LP(T96),CHAS PKG(Z85),(20U) (2007-2008) (2007 - 2008).
Cost: $169.56

Item Number:010
Part Number: 15920028
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(BLUE). Required: 01
For: ST1 CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(20U),(EXC FRT FOG LP(T96),CHEVY XTREME PKG(V4A) (2007-2007) (2007 - 2007).
For: ST1 CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(20U),(EXC INTERIM CONTROL CHANGE:REFER TO VEH OPT LABEL FOR VERIFICATION(CNV),FRT FOG LP(T96) (2008-2008) (2008 - 2008). Cost: $110.14

Item Number:010
Part Number: 12335805
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(GRAY)(CUT FOG LAMP HOLES AS NEEDED). Required: 01
For: ST1 FRT FOG LP(T96),'OFF ROAD' CHAS PKG(Z71),CHAS PKG(Z85),(EXC SPORT PERFORMANCE PKG(B4U) (2004-2007) (2004 - 2007).
For: ST1 FRT FOG LP(T96),(EXC SPORT PERFORMANCE PKG(B4U) (2008-2008) (2008 - 2008).
For: ST1 FRT FOG LP(T96),(EXC SPORTS EQUIP SALES PKG(PFL) (2009-2011) (2009 - 2011).
For: ST1 FRT FOG LP(T96),SPORT CHAS PKG(ZQ8),G M C(Z88) (2006-2007) (2006 - 2007).
Cost: $113.44

Item Number:010
Part Number: 12335806
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(GRAY)(W/O FOG LP OPENINGS). Required: 01
For: ST1 (EXC SPORT PERFORMANCE PKG(B4U),FRT FOG LP(T96) (2008-2008) (2008 - 2008).
For: ST1 (EXC SPORT PERFORMANCE PKG(B4U),FRT FOG LP(T96) (2009-2011) (2009 - 2011).
For: ST1 BASE LEVEL CONVENIENCE DECOR PKG(YC0),CONVENIENCE PKG #1(YC1),DECOR PKG LEVEL #3(YC3),'OFF ROAD' CHAS PKG(Z71),CHAS PKG(Z85),(EXC SPORT PERFORMANCE PKG(B4U),FRT FOG LP(T96) (2004-2007) (2004 - 2007).
For: ST1 SPORT CHAS PKG(ZQ8),G M C(Z88),(EXC FRT FOG LP(T96) (2006-2007) (2006 - 2007).
Cost: $111.45

Item Number:010
Part Number: 12335807
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(MOLDED IN BLACK). Required: 01
For: S1 FRT FOG LP(T96),CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(41U),(EXC CHEVY XTREME PKG(V4A) (2006-2007) (2006 - 2007).
For: ST1 FRT FOG LP(T96),CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(41U) (2008-2008) (2008 - 2008).
For: ST1 SPORT PERFORMANCE PKG(B4U),CHAS PKG(Z85),(41U) (2008-2008) (2008 - 2008).
For: ST1 SPORT PERFORMANCE PKG(B4U),FRT FOG LP(T96),CHAS PKG(Z85),(41U) (2004-2007) (2004 - 2007).
Cost: $134.49

Item Number:010
Part Number: 19181761
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(PAINT TO MATCH). Required: 01
For: ST1 SPORTS EQUIP SALES PKG(PFL) (2009-2011) (2009 - 2011).
Cost: $258.52

Item Number:010
Part Number: 12335810
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(RED). Required: 01
For: S1 FRT FOG LP(T96),CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(74U),(EXC CHEVY XTREME PKG(V4A) (2006-2007) (2006 - 2007).
For: S1 FRT FOG LP(T96),SPORT CHAS PKG(ZQ8),CHAS PKG(Z85),(74U) (2004-2005) (2004 - 2005).
For: ST1 SPORT PERFORMANCE PKG(B4U),FRT FOG LP(T96),CHAS PKG(Z85),(74U) (2004-2008) (2004 - 2008).
Cost: $217.62

Item Number:010
Part Number: 15811515
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(RED). Required: 01
For: ST1 CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(74U),(EXC FRT FOG LP(T96) (2006-2008) (2006 - 2008).
Cost: $137.44

Item Number:010
Part Number: 15811514
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(WHITE). Required: 01
For: ST1 CHEVROLET(X88),(50U),(EXC FRT FOG LP(T96) (2006-2008) (2006 - 2008).
Cost: $171.11

Item Number:010
Part Number: 12335809
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(WHITE). Required: 01
For: ST1 FRT FOG LP(T96),(50U) (2008-2008) (2008 - 2008).
For: ST1 FRT FOG LP(T96),(50U),(EXC CHEVY XTREME PKG(V4A) (2004-2007) (2004 - 2007).
Cost: $198.01

Item Number:010
Part Number: 12335808
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(YELLOW)(W/FOG LAMP OPGS). Required: 01
For: ST1 FRT FOG LP(T96),(43U) (2004-2007) (2004 - 2007).
Cost: $191.91

Item Number:010
Part Number: 15811513
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR(YELLOW). Required: 01
For: ST1 CHEVROLET(X88),SPORT CHAS PKG(ZQ8),(43U),(EXC FRT FOG LP(T96),CHEVY XTREME PKG(V4A) (2006-2007) (2006 - 2007).
Cost:$112.89

Item Number:010
Part Number: 88981086
Description: FASCIA. Front and Rear Bumper/Fascia Face
FASCIA,FRT BPR. Required: 01
For: S1(03-43-53) CHEVY XTREME PKG(V4A) (2005-2008) (2006 - 2008).
Cost:$572.72


Item Number:011
Part Number: 15733971
Description: RETAINER. Bumper/Fascia. Front and Rear Bumper/Fascia Face.
RETAINER,FRT BPR FASCIA(13MM)(01.272). Required: 09
For: ST1 (2004-2011) (2004 - 2011).
Cost: $2.67
 

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Front Bumper Fascia Replacement (Canyon/Colorado)



Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the front bumper (1) assembly. Refer to Front Bumper Replacement .
  3. Remove the push-pins retaining the fascia (2) to the front bumper.
  4. Pull the fascia straight forward to remove.

Installation Procedure

  1. Install the fascia (2) to the front bumper.
  2. Install the push-pins retaining the fascia to the front bumper.
  3. Install the front bumper (1) assembly. Refer to Front Bumper Replacement .
  4. Lower the vehicle.


http://www.355nation.net/forum/how-exterior/21022-how-remove-bumper-valence.html
 

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Front Bumper Replacement

Removal Procedure



  1. Remove the grille. Refer to Grille Replacement.
  2. Remove the fog lamps, if applicable. Refer to Front Fog Lamp Replacement.
  3. Remove the bolts that attach the bumper bracket to the frame.
  4. Remove the bumper from the vehicle.
  5. Remove the bolts that attach the bumper bracket to the bumper.
  6. Remove the front bumper fascia (2) from the bumper (1). Refer to Front Bumper Fascia Replacement.

Installation Procedure

  1. Install the front bumper fascia (2) to the bumper (1). Refer to Front Bumper Fascia
    Replacement
    .
  2. Install the bumper bracket to the bumper.
    Caution: Refer to Fastener Caution in the Preface section.
  3. Install the bumper to bracket bolts and tighten to 40 N·m (30 lb ft).
  4. Install the bumper to the vehicle.
  5. Install the bumper bracket to frame bolts and tighten to 40 N·m (30 lb ft).
  6. Install the fog lamps, if applicable. Refer to Front Fog Lamp Replacement.
  7. Install the grille. Refer to Grille Replacement.
 

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Grille Replacement

Removal Procedure



  1. Open the hood.
  2. Release the retainer on the daytime running lights (DRL), park lamp assembly.
  3. Remove the DRL, park lamp assembly.
  4. Use a flat-bladed tool in order to release the retainers that retain the grille to the body.
  5. Lift the grille out of position.
  6. Remove the grille from the vehicle.

http://www.355nation.net/forum/how-exterior/17-how-grill-removal-pics-video.html
 

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2,692 Posts
Good write up !!! I just love to find a reason to use my Dremel tool... But not enough to hit a deer !!! LMFAO:salute:
 
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