Good afternoon all, I am working on restoring a 91 Toyota MR2 and the front bumper has a crack where the front splitter mounts to the bottom. There is very little material to work with. I was looking at 3M flexible bumper repair patches but I think where this lip doubles back from the front of the bumper that isn't going to work. Any suggestions? I am not to the painting stage yet, I'm mostly looking for a flexible structural repair that will last long term. I'm not 100% sure on the material but I'm guessing FRP? There are areas where it looks like a white powdery material, but its flexible on the wide parts.
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So you were guessing FRP. Then you mentioned white powdering stuff.... that usually indicates SMC or sheet molded compound. It would look a lot like FRP however it is pressure molded with the mold relase right in the resin. This makes it so the manufacturing concern does not have to use a mold release in the process. When the mold opens the piece pops out. The only downside to working with SMC is that you must use SMC compatible materials when doing the repair. Most bondos, long and short haired fiberglass fillers, etc., will state this right in the P sheet or on the can. Now if it was me I'd make a call over to the people at Polyvance to get the "best" method for repairing this. They have helped me many times over the years... www.polyvance.com

I will definitely check them out, thanks. Attached is a closeup of the the top part of the bumper edge at the front trunk (Frunk) to get a better idea of what's under the paint.

Well, that just kind of deepens the mystery from my end. Usually those yellowish plastics are some type of urethane. Still looks like it came out of some kind of pressure molding. That is a good pic. you have there.... I'd get an email address from a tech. at Polyvance and send that to them. They can probably I.D. that....

I talked to support at polyvance, he said that it thermoset polyurethan, PUR. They suggested to repair with an airless plastic welder and to be sure not to melt the base material and to use their urethane welding rod- which acts like an adhesive rather than mixing with the base material. Now where the crack is in this material makes the whole process outlined on their video pretty daunting.

https://www.polyvance.com/video/thermos ... tic-welder

Well, at least it looks like a decent repair since it applies the new plastics to both side however I am assuming you can only get to the one side with it mounted? Oh, and if you do decide to go this route I know of at least one guy that bought this unit.... https://www.amazon.com/JOUNJIP-Plastic- ... D_BwE&th=1 It does include that "shoe" tip for feeding the material into the area....