How to Make Vinyl Film Removals Easier and Faster

By Jim Hingst

Jim Hingst offers tips on removing vinyl graphics to save time and improve job profitability.

The process of removing vinyl films generally requires the use of  both heat and chemicals.  Some removers contain hazardous chemicals, such as toluene, that can cause health problems.  Before using any chemical remover, read the manufacturer’s MSDS sheet and instruction bulletin. Always wear the recommended safety equipment.

When working with propane torches or heat guns, use caution.   Heat sources can raise the temperature of the substrate hot enough to blister or burn your fingers.  Careless use of heat sources can also cause fires and explosions.

Removing graphics is unpredictable. Film from the same roll of vinyl, applied to different substrates will remove with various degrees of difficulty.  A variety of factors determine how easily graphics can be removed. These factors include the age of the graphic and the substrate’s condition at the time of application.  

Adhesion increases with time making removals increasingly difficult the longer that a graphic is on the substrate. Graphics applied to newer and smoother factory-paint finishes remove more easily, than those applied to old, pitted surfaces. A rough finish provides the adhesive with a greater total surface area for a stronger adhesive bond.

The first step in the removal process is to heat to the graphics.   Heat softens the  facestock and its adhesive allowing the vinyl to be more easily peeled from the surface.   By getting a large area hot you can peel larger pieces of film off at one time.  

If you are removing small letters, a small handheld propane torch or industrial heat gun provides sufficient heat.  If the graphics cover a large area, however, you will need much larger torch, such as a weed burner.  With an extra-long hose, the propane tank can be left on the ground, safely leaving the scaffolding free of clutter.

Heat a large section of the truck surface for approximately one minute. Keep the flame moving, so you do not to burn the vinyl or substrate. Use caution when heating graphics on plastic substrates. Heat can warp the substrate.

After heating, use a fingernail, a Teflon®-coated plastic scraper, such as the Lil Chizler, or a plastic blade to lift the graphic’s edge. When lifting the vinyl from the surface,  pull the film at a low angle (preferably less than 45°) close to the work surface.  

Whether you use a heat gun, propane torch or steamer, the secret is to apply the correct degree of heat, something that can only be learned by trial and error. If the vinyl is too hot or too cold, not only will you leave the adhesive, but the film itself will break into little pieces. At the optimal temperature, the film will remove more easily, in large pieces and you will reduce the time it takes to perform the removal.

To remove the adhesive residue, after film removal, requires the use of a chemical adhesive remover. Keep a variety of chemicals with you, including PrepSol™, kerosene, lacquer thinner, xylene and a citrus-based remover, when going on a removal job.  What works wonders one day, may not work the next. 

Start with a less aggressive and safer remover, such as Rapid Remover,  before trying the stronger and usually more toxic chemicals. Using this approach reduces the risk of paint damage and minimizes any health hazards.

Before using removers, always test the chemical on an inconspicuous spot of the substrate to make sure the remover doesn’t react with the paint. Repainted vehicle surfaces are especially susceptible to damage from chemical removers.

Spray the remover on the adhesive residue. Wait for the chemical to react with the adhesive residue.  When the adhesive softens to a jelly-like substance, use a squeegee to scrape the gel from the surface. Old rivet brushes can scrub adhesive off the rivet heads.

Scraping off jellified adhesive is messy.  To keep from spreading the mess all over the substrate, mask off the area around the graphic with masking tape and kraft paper or use RTape application tape.  If you are removing large areas of adhesive, some of it will likely end up on the shop floor, so cover the area underneath your scaffold with brown kraft paper or application tape to aid clean up. 

In some cases, adhesive residue remains on the surface. When this happens, spray the residue with remover, wait for the adhesive to soften, and wipe the surface clean with rags or paper towels. Finish cleaning the surface by wiping with isopropyl alcohol.

The surface must be perfectly clean before installing new graphics. Applying new vinyl over old adhesive practically guarantees film failure, because the adhesive will absorb the chemicals like a sponge. If the new graphics are applied over the residue, the remaining remover will attack the new adhesive. This can cause new vinyl to bubble, peel or fall off.

Cold removals

For some removal jobs, using heat is impractical. For example, heating a window with a torch can result in glass breakage. When you cannot use heat, try using razor scrapers and plastic abrader wheels to aid film removal.

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Vinyl Application Videos

Squeegee Technique. Nothing is more basic in vinyl application than the squeegee. But some squeegees work better than others. And there are right ways and wrong ways to use this simple tool. This video clip reviews squeegee selection, squeegee care and squeegee technique. Click to Link

Wet Applications. Dry applications are typically recommended for most vinyl applications. For those exceptions to the rule, this instructional video explains the right way to perform a wet application. Click to Link

Application of Window Graphics. Installing vinyl graphics on glass can be challenging, because the adhesive aggressively grabs onto this high energy surface. Repositioning graphics on window is generally difficult, if not impossible. This instructional video explains how to dry apply window graphics right the first time. It also describes the necessary steps required for surface preparation. Click to Link

Transferring Frosted Window Graphics Films.  Because frosted window films are highly textured, transferring cut vinyl graphics can be problematic. This video provides direction in selection of the right application tape and how to apply these films quickly, easily and without problems. Click to Link

3-Step Surface Prep. This instructional video describes how to properly clean the surface of a vehicle before applying pressure sensitive vinyl graphics to a trailer or doing a full wrap of a car or van. This three step surface prep involves detergent washing, solvent cleaning and a final wipe down with IPA. Click to Link

Vinyl Application Over Rivets. Applying vinyl graphics on vehicle surfaces with rivets is challenging for most sign makers. Vinyl failures to these surfaces are all too common. This video demonstrates some tips and procedures, used by professional decal installers, which will make these demanding applications easier and more trouble-free.  Click to Link

Vinyl Application to Corrugations. Learn how to apply vinyl graphics to corrugations in a relaxed state. Forcing films into the valleys of corrugations puts too much mechanical stress on the film. Sooner or later, the vinyl will lift or tent in valleys. Click to Link

Applying Air Egress Vinyls. Vinyl films with air egress release liners have almost eliminated bubbles and wrinkles from applied graphics. Air egress release liners with their highly textured surface structure are problematic. Not much will stick to these liners other than the vinyl film. At RTape our best premask solution for air egress liners is a special Conform® tape called 4761RLA. Click to Link

About Jim Hingst: After fourteen years as Business Development Manager at RTape, Jim Hingst retired. He was involved in many facets of the company’s business, including marketing, sales, product development and technical service.

Hingst began his career 42 years ago in the graphic arts field creating and producing advertising and promotional materials for a large test equipment manufacturer.  Working for offset printers, large format screen printers, vinyl film manufacturers, and application tape companies, his experience included estimating, production planning, purchasing and production art, as well as sales and marketing. In his capacity as a salesman, Hingst was recognized with numerous sales achievement awards.

Drawing on his experience in production and as graphics installation subcontractor, Hingst provided the industry with practical advice, publishing more than 150 articles for  publications, such as  Signs Canada, SignCraft,  Signs of the Times, Screen Printing, Sign and Digital Graphics and  Sign Builder Illustrated. He also posted more than 325 stories on his blog (hingstssignpost.blogspot.com). In 2007 Hingst’s book, Vinyl Sign Techniques, was published.  Vinyl Sign Techniques is available at sign supply distributors and at Amazon. 

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© 2016 Jim Hingst