I've dragged the Fairing back from the shop...

[renegade_xs11g]

Think I want to make it into a quick change type thing...
Put it on for long trips...SWMBO and I go on longer rides in the summer
Off, the rest of the time....

So I get looking at it, damaged from the wreck, but not that bad
cracked in 2 places, around the head light,
and along the inside bottom near the mount,

All I have on hand is a fiberglass repair kit, but
I've never tried to do bodywork....never had the patience for it....
oh well, I was better at turning wrenches

I'll get pics, up tommorow

Any words of wisdom? Do's... Don'ts... Thing's I'll need

Obviously, don't work on it in the basement....But, can this be done outside...
is it to cold? Will I need a mask? 'Course I could use a good buzz, just don't wanna kill myself

[CatatonicBug]

You will definitely want a cartridge-type mask for any sanding on fiberglass. If you've ever gotten it in your skin, you can only imagine what it can do in your lungs. Think of the body work much like plaster, but in flexible sheets. Cut away any damaged parts and sand it all nice and smooth, and sand away any paint on the surface until you are down to bare fiberglass. Get the fiberglass sheets wet with resin, and smooth it over the area you are repairing. Get all the air pockets out. Let it harden, and sand like crazy. Use bondo to get a final glass-like finish.

My first job out of High School was in a machine shop, making animated figures for the Theme Park industry. I made several figures (moving and static) that are currently on display in the Universal Studios Islands of Adventure park in Florida. We had a crew of guys who did this fiberglass stuff all day long. It makes a mess, and it does help if the temps are warmer. They used propane heaters to warm up the area so the resin and the paint would dry.

[latexeses]

If you have a TAP-Plastics anywhere around there, get in there to see them. They have some really good information and sell anything you need to make a repair with fiberglass, carbon fiber or Kevlar. I went in looking for information on repairing a canoe and left with everything I needed including a good bit of knowledge, good tips and other things you don't get from a book.
Now for the first question. Is your fairing fiberglass???

[ELDR]

Hi

If thats a ABS plastic fairing, Vetter or similar. don't use fiberglass. You will need to find an ABS plastic epoxy to patch. Vetter sells a "Hotcha Repair Kit" but other epoxy for ABS will work. Using the Hotcha kit will make it as strong and flexible as new.

http://www.craigvetter.com/pages/Onl...r-Hotcha-60133

[renegade_xs11g]

Ok, so I have the big Yamaha Fairing,
it's not fiberglass, it's plastic.....3 cracks not 2
the 2 around the headlight don't meet
and it's the outside bottom not inside









right hard bag lid is cracked, so is the box tho not nearly as bad, the hinge is still on it



right lower fairing, broken into 2 pcs.



left lower, small crack




So, since it's plastic, why can't I use fiberglass,
most would fill with just resin,
obviously, gonna need some reinforcing on the lid, and right lower

[audio_mekanik]

I know a body shop guy that fixes cracked bumpers on cars all the time. He calls it plastic welding. He uses a pocket torch to melt the plastic, works in more plastic from a strip he cuts from scrap bumpers. He explained that it is kind of like tig welding. Then sand, sand, sand, filler, sand, sand, and repeat He has a lot more patience than me for sure.

[audio_mekanik]

Forgot to mention that is how he fixed my cracked sidecover

[ELDR]

ABS plastic is a thermally formed plastic that adhesives and fiber glass resins don't adhere to very well. Might look solid but will peel away. The fairing distorts a lot as you hit a bump or pass bug 2 and the fiberglass will pop off.

You need either a solvent adhesive or epoxy that bonds well to ABS or you can use a hot air torch to weld the ABS.

I used a two part epoxy weld made by Plermaoxych that worked well and picked up some scrap ABS plastic from a plastic fabricator to use as reinforcing. Used the epoxy for filling holes and a to make a few small missing pieces. There is also a great plastic solvent kit that is strong and will join cracks directly without reinforcing it called Plastex

http://www.plastex.ca/default.asp


See these as well

http://www.xs11.com/forum/showthread...ght=abs+repair

http://www.xs11.com/forum/showthread...ght=abs+repair

http://www.xs11.com/forum/showthread...ght=abs+repair

http://www.craigvetter.com/pages/Onl...r-Hotcha-60133

[CatatonicBug]

So, since it's plastic, why can't I use fiberglass

Well, it's for the same reason you weld metal, and not use fiberglass. The damaged part needs to be reconnected with a material that has the same molecular structure as the original part. Otherwise, they will not properly adhere, and will break apart under stress. Plastex or professional plastic welding is your best bet on plastic parts.

[BigDick]

Gotta second CatatonicBug on this one, when I was working for my stepdad in his body shop we'd get cracked bumpers in a lot. You V out the crack and use a plastic welder, which is basically a fancy soldering iron. One head has a paddle tip the other is a foot shape with a funnel molded onto it, you feed your filler material down the funnel and it comes out the bottom of the "foot" and joins your base material. then filller and sand and repeat.

[John]

I repaired some cracks in the fairing of Wildkat's FJ11 by melting some stainless steel screen into the plastic by using a soldering iron. Just cut a stip of screen about one inch wide and as long as the crack. Make sure you are working on the back side of the crack, or at least where it can't be seen. Lay it over the crack, and use the iron on top of the screen to melt the plastic under the screen. The melted plastic will ooze up through the mesh and when it cools it will 'lock' onto the screen and make a permanent repair. Just do your cosmetic work on the outer surface, and you'll have a solid, permenant repair.

[ELDR]

Another good tip is to drill a small hole at the end of the crack before the repair. Then fill the hole as you finish the repair. The small hole stops the the crack from spreading further.

[renegade_xs11g]

Thanks

As some may know my bike is for sale,
I have a couple of people interested
if I don't sell it, I will find a welding kit and go that way,
I've been done the wrong way to fix things before, no on likes having to re-repair something, least of all me

[latexeses]

renegade,
Take a serious look at this website. They have solvents for repairing ABS and other plastics.

http://www.tapplastics.com/

I thought they were a nationwide chain but it looks like they are left coast only. You can mail order. I have had good luck buying from them.
Give them a call they can set you up with the proper solvents and fillers.

[cywelchjr]

As some may know my bike is for sale,
I have a couple of people interested
if I don't sell it, I will find a welding kit and go that way,
I've been done the wrong way to fix things before, no on likes having to re-repair something, least of all me

It's a bummer seeing you sell that nice ride. I'm not sure much of anything could get me to part with mine. Of course I've only had it since Nov, but I get more attached to it all the time.

Do consider the plastic welding if you don't sell it though, as that is from my experience the best way to fix this type of plastic.