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This page shows how you can do a repair on a broken mirror cover at home. Materials needed are:  SEM plastic bumper epoxy, a small piece of  poly plastic sheeting, a small piece of plastic bug screen, rubbing alcohol, a grey 3M scotch pad, 80, 240, 400 and 800p grit sandpaper, polyester finishing putty, a small spreader, masking tape and newspaper, a can of primer that can be sanded and a can of black (or color of choice) trim paint.

Broken Mirror Cover

Don't lose the pieces that came out of the mirror.

Side view, Broken mirror cover

Pieces that broke off

Two pieces, Plastic repair epoxy and 80 grit sand paper.

Rubbing Alcohol to clean the broken pieces and the mirror cover.

Clean all surfaces with rubbing alcohol and sand with 80 grit the broken pieces and anywhere where you are going to apply the epoxy. This is to ensure good adhesion.

Mix epoxy and glue cleaned and sanded peices in place.

Follow mixing instructions on the epoxy carefully and wear gloves when attaching pieces.

Supporting the broken pieces with a patch behind the cover.

Take the poly plastic sheeting, cut a piece slightly larger than the patched area. Spread a layer of plastic bumper epoxy on the sheeting. Lay plastic bug screen on top and add another layer of epoxy on top of bug screen. Pick this peice up and stick it to the inside of the mirror cover, using it to support the back side of the repaired area. Let it set for 5 minutes and remove poly from the epoxy. The poly sheeting side is only used to carry and spread the patch on the repair.

Epoxy is hardened

After letting the epoxy dry completely, half and hour or more.

Sanding repair

Take the 240 grit sand paper and sand off the repair area, removing any excess epoxy.

Two part polyester finishing putty (putty and cream hardener)

This particular brand is not my favourite, I prefer Wurth brand products.

Mix putty according to product instructions

Make sure it is thoroughly mixed.

Spread it evenly over the repair area, both sides.

The objective is to smooth over any low spots and fill cracks to make a smooth surface for painting. Let it dry 20 minutes or more.

Sand excess putty off all surfaces with 240 grit sandpaper, then again with 400 grit sandpaper.

Mask off the background of vehicle at least 4 feet in all directions around the part to be painted. Newspaper is not recommended but if you do use it overlap 3 layers at least to prevent paint from seeping through. Professional masking paper is preferred as it has a plastic coating on one side to prevent paint seepage.

Sand smooth the inside area as best as you can.

Scuff over all areas to be painted with 3M gray scotch pad

Primer

Primer colour is not that critical, but it does make it easier. In this case, the mirror cover was black, so we chose a black primer. It must be a primer surfacer product suitable for plastic and be sandable. Prime the repaired area with 3 coats, allowing 10 minutes drying time between coats. Three medium coats of primer are better than one thick coat. Sand primer area with 400 grit sand paper after the 3rd coat has completely dried. Add one more coat or more if necessary to the entire area that you are going to paint.

Paint

Once primer is completely dry, lightly sand the entire area to be painted with 800 grit sand paper. Make sure you blow all dust off. It is now ready for your first coat of paint. It may require up to 3 coats of paint. Make sure you allow 10 minutes flash time or drying time in between coats.

Shows mirror primed and ready for paint.

Finished repair

Let paint dry completely and then remove paper and check for any overspray. If you find overspray you can polish it off with a microfinish or fine cut polish.

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