The bumper cover on my ZJ is not the correct one for my model (Limited) and while most people would never notice, I do and it does bug me even though it's been trimmed quite a bit to clear my 35's.
My original one was cracked pretty bad and the PO really did a bad job of painting it with a rattle can and there were holes in it from a previous license plate bracket.
I had another 96-98 bumper cover laying around, but it was not the Limited model and the lines are slightly different. It too has some holes from a front license plate, and I temporarily drilled more holes in it and mounted a Euro plate on it from a friend in Czech for a different look.
Well, I finally came across another good Limited front cover in the junk yard a couple of weeks ago that was in pretty good shape. These things are really hard to find used that aren't all beat to hell, chipped, cracked or broken in some way. The only thing wrong with this one are a couple of light scratches and yes, previous holes from a front license plate.
Here is what I did to fill the holes.
- Clean the area very well with soap and water
- Using a soldering gun and another piece of the same bumper cover material left over from when I trimmed my old one, heat and melt the plastic into both sides until it's relatively flat. Put more in than you think you need.
- After the plastic has cooled, take a sharp razor blade and carefully shave off any high spots.
- Lightly sand the repaired area with 220 grit sand paper. Use a block to keep the panel straight.
- Fill any remaining imperfections with either more plastic, glazing putty or bondo. I chose to use glazing putty because there were only tiny pin holes and I already put the soldering gun away and got lazy.
- Lightly sand again using 400 wet/dry sand paper and it's ready for paint and primer.
I need one more light coat of glazing putty on the holes I filled in and a couple of minor scratches. More pics once I get this done and ready for paint.
Obviously the same thing can be done with the textured bumper covers, but you have to be real careful when melting the plastic in. You won't be able to fill any imperfections on the raw cover so take your time.
This procedure also works well for large cracks. Just heat and melt some donor plastic into the crack from both sides.