Apologies for not replying earlier, I've been on a mobile device and except for one-liners, I HATE
typing with a touch-pad.
Originally Posted by kirkdickinson
Isn't it kind of like brazing except with plastic? Where do you get the "welding rod"?
Not quite, the filler material is the same as the base and the base material has to melt as well as the filler, so it's pretty much the same as oxygen-acetylene welding of steel.
The technique -prep and bead forming- can be pretty much the same as well, just the temperature is lower.
If the innards of the case can't be removed, I've used a specially ground soldering iron tip, the somewhat uncontrollable penetration control of a hot air welder may melt the (styro-) foam material inside the shell.
I have used strips cut from pieces of smashed cases with great success, but any modern auto body shop should carry ABS filler rod as well.
They weld dashboards and bumper outer shells daily.
In a recent thread about the same subject, someone pointed out MC shops as candidates for filler material as well.
Some hardware stores may carry hard plastic filler rods, but usually their products are for welding plastic floor materials.