I made a 2" tear in my from facia when clipping a curb at 2MPH. Made me sick (so sick, I did NOT take photos).
I went to a professional autobody paint store a bought:
$30 for TPO kit (bumper repair epoxy -
Duramix)
$90 for matching base color paint, and clearcoat
$15 for misc supplies
Here's the work:
-Took off the front facia (1-2 hrs)
-Ground down the edges of the tear to a 3/16" wedge on both sides, inside & out. (a CAREFUL hour with a Dremel)
-Drilled off-set 1/16" holes every 1/4" in the "wedge".
-Prep'd the plastic with TPO bonding prep.
-Epoxy'd the back with fiber reinforcement (included in the kit), and let it set (minutes).
-Epoxy'd the front.
-Block-wet-sanded it with 320grit (1/2 hour)
-Painted it with Flexible primer, and re-sanded with 320.
-Repeated the primer and sanding steps about 8-10 times - until PERFECTION - in all about 5 hours (I'm not a "pro").
-Applied a thin base (color) paint with an inexpensive gun -
HarborFreight
-Wet sanded with 1000grit and applied two more thin, plus one thick coat. - (2-3 hrs).
-Applied ONE clearcoat as the instructions state: full medium coat, wait 15 minutes, apply the 2nd full coat and leave it alone for at least 24 hours. (I bought a 2nd paintgun for the clear on the advise of a pro - good advice.)
The next day I rubbed out a little overspray, and she looks like glass (the rest of the car). A 100% paintmatch. I'd post a photo, but it looks factory, so what's the point?
I hung the facia back on the car - another 2 hours of PAIN. My secret was to remove the hood alarm switch, so I could get a wrench on the top bumper reinforcement bolt on the passenger side.
In all, I fugure I was in to it for at least 20 hours, but what a savings!
If you're not up to it - ask at an AUTOMOTIVE paint store for someone that does side work and save a ton. (PS. Don't give them the car to work on - take off the front and give them JUST that.)