Motor Guard Magna Stitcher MS-2500

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Summary

IMPORTANT SAFETY INSTRUCTIONS

General Safety Precautions

Observe all warnings and instructions, keep work area clean, maintain tool, and use manufacturer parts.

Electrical Safety and Grounding

Connect to a properly grounded outlet, do not modify the plug, consult an electrician if unsure.

Personal Protective Equipment (PPE)

Wear a full face shield, adequate gloves, and clothing to protect against injury and burns.

Environmental Operating Conditions

Do not operate in explosive atmospheres; use in well-ventilated areas only.

APPLICATION

Power Connection and Environment

Connect to grounded supply; unit is for indoor, clean, dry environments only.

Control Panel and Power Settings

Operate via power switch and level knob for low, medium, or high settings.

GENERAL REPAIR PROCEDURE WITH MAGNA STAKES

Cooling, Trimming, and Finishing

SURFACE REPAIR WITH IRONING TIP

Overview

The Magna-Stitcher™ Plastic Repair System, Model MS-2500, is a specialized tool designed for the structural repair of various plastic parts. This system operates by welding rigid stainless steel stakes into the surface of plastic, creating a permanent repair for cracks and other damage. It is versatile enough to address repairs on flat surfaces, tabs, holes, ribs, and both inside and outside corners.

The Magna-Stitcher™ System is suitable for repairing a wide range of automotive components, including bumpers, fascias, spoilers, headlamp brackets, radiator brackets, interior components, underbody structures, wheel wells, panel mounting tabs, and virtually any thermoplastic part. Its economical design also makes it ideal for quick, on-the-vehicle repairs for components like mounting tabs and other out-of-sight parts. The process is straightforward: simply stitch and go.

Before operating the tool, it is crucial to read and understand all warnings and instructions to prevent electric shock, fire, or serious personal injury. The work area should be kept clean and well-lit. The tool itself should be maintained in top condition, and any malfunctions should be addressed by obtaining service from the manufacturer. Only accessories and replacement parts provided by the manufacturer should be used.

For safe operation, the tool must be connected to a properly grounded outlet in accordance with all local codes and ordinances. The grounding prong should never be removed or modified, and adapter plugs should not be used. If there is any doubt about the plug's grounding, an electrician should be consulted. Bodily contact with grounded surfaces should be avoided.

Personal protective equipment is mandatory when operating the welder. A full face shield, meeting ANSI Z87.1-2003 standard, is required at all times to protect the face and eyes from flying parts. Adequate gloves and clothing are also necessary to reduce the risk of burns. Parts should be allowed to cool before handling.

The tool should not be operated in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust, as welders create sparks that can ignite these substances. It should only be used in well-ventilated areas. Welders generate heat, which can ignite surrounding materials, potentially causing fires.

To prepare the Magna-Stitcher System for use, connect it to an approved power supply, paying close attention to the safety instructions. If an extension cord is necessary, it must be a three-wire, grounded cord of the proper amperage. This unit is designed exclusively for indoor use in a clean, dry environment.

The unit is turned on by switching the main Power Switch to the "On" position. A Level Knob allows selection of one of three power positions:

Low Setting (Green LED): Ideal for thin sections and detailed work.
Medium Setting (Yellow LED): Suitable for general repairs.
High Setting (Red LED): Recommended for thicker sections and heavy work.

The Work Lamp illuminates in any of the three power positions and remains on regardless of whether the Trigger Button is depressed. To prevent eye damage, users should not stare directly into the light beam or point it directly at others. The appropriate stake type should be chosen based on the area to be repaired.

Preparation of the work area involves removing all dirt, oil, and dust. Repairs are typically made on the inside surface of the panel. Removable foil tape can be used on the outer surface to hold the position during stitching.

For general repair procedures with Magna Stakes, insert the stake into the electrodes. Three positions are available for inserting stakes at different angles. Place the stake against the surface to be repaired, applying moderate pressure, then depress the Trigger Button to heat the stake. While maintaining pressure, allow the stake to sink halfway through the thickness of the workpiece. Once inserted to the proper depth, twist the stake slightly to lock it into the panel. Allow the stake to cool for 2 or 3 seconds before removing the tool. Exposed ends of the stake should be trimmed using wire cutters. Extreme care must be taken when trimming stakes, as flying pieces can cause injury to the operator or bystanders. Eye protection must be worn at all times. After trimming, complete any cosmetic repair on the front of the panel as needed.

For flat areas, an S-Shaped Magna-Stake™ is inserted into the electrodes and placed across the crack. The stake is inserted halfway through the panel thickness and given a slight twist before cooling. Stakes should be spaced at 1/2 to 3/4 inch intervals or as needed for strength.

For tabs and thin sections, an M-Shaped Magna-Stake™ is used. It is inserted across the crack, halfway through the panel thickness, and additional stakes are added as needed for strength.

For inside corners, a V-Shaped Magna-Stake™ (MS2006) is inserted across the crack, halfway through the panel thickness, and given a slight twist before cooling. Stakes are spaced at 1/2 to 3/4 inch intervals or as needed.

For outside corners, a W-Shaped Magna-Stake™ (MS2007) is used. It is inserted across the crack, halfway through the panel thickness, and given a slight twist before cooling. Stakes are spaced at 1/2 to 3/4 inch intervals or as needed.

After any stake repair, trim the stake ends and complete any necessary cosmetic repair on the front of the panel.

The ironing tip can be used for surface repair to smooth rough areas and build up low areas prior to final repair. Insert the Magna-Stitcher™ Ironing Tip (MS2045) into the electrodes. Depress the Trigger Button to heat the tip, then apply moderate pressure with a slight rotary motion, allowing the spring-like tip to roll over the area to be repaired. Continue until the damaged area is smooth, then complete the repair using conventional methods.

Motor Guard Corporation provides a limited warranty, ensuring products are free from defects in workmanship and material. If a product fails due to such a defect within one year of purchase, Motor Guard Corporation will repair or replace it without charge, excluding transportation costs. The product must be returned to the factory, transportation prepaid, with prior return authorization and shipping instructions. This warranty does not cover normal wear and tear, damage from neglect, misuse, or accident, nor does it cover any direct, indirect, or consequential loss, damage, or expense arising from the product's non-function.