side cover repairs

[old_skool]

Finally getting around to doing a resto thread on my side covers, I'm concentrating on repairing and restoring those pesky broken and seemingly expensive to replace side covers, these may not be XS1100's(GS1100) but they were in worse condition than the Specials so I thought these would be more suitable due to their deplorable condition. I already started the rough sanding on the first one and popped the broken plastic back in place(always tough without breaking completely) And will grind a grove in and along the crack with my dremel but not all the way through, then proceed to fill it in with the putty, and sand after it cures, followed by very fine sanding. Then I will proceed preparing it with sand-able primer. The second one has actual pieces missing, this will be fun...no really, I'm actually pretty good at making something from nothing, especially when you have nothing, you get good at it. stop here for pics and further progress.







Will also be using some superglue, cardboard for mold backing, gotta wait for that pesky dremel to charge...zzzzzzz

[crazy steve]

The one thing I would suggest is to 'overlap' the repairs on the back side by at least a 1/2" all around for strength (about 1/8" thick). When I fixed a pair, I had trouble with them re-breaking when flexed until I did that.

[old_skool]

Yeah, I had planned on something for backing support, but haven't decided on what yet, I have some very thin sheetmetal I may cut and epoxy in place, still thinking on what I want to use.

[crazy steve]

I don't think you need to use any 'other' material, just spread your repair goo out more on the backside. I used the superglue/baking soda mix, and my cracks kept opening up until I 'coated' the whole area around the fix. That did the job...

[XS1100_OEM4ME]

Fiberglass

I would cut a backing patch about 1/2" + bigger then the hole / crack, to use as a backing. The type that looks like a bunch of fibers, not the kind that looks like cloth. Sand the contact area with 80grit, saturate the cloth with resin mixed with hardner then attach and let cure, finish the front with the fillet, JIMHO

Yeah, I had planned on something for backing support, but haven't decided on what yet, I have some very thin sheetmetal I may cut and epoxy in place, still thinking on what I want to use.

[old_skool]

not using any fiberglass

[Schming]

Jat...

"Then I will proceed preparing it with sand-able primer."

http://www.krylon.com/products/fusion_for_plastic/

Hey Old School, the above link is what I used on my XJ750 Mid Max plastic air filter trim. Painted them 2 years ago and they seem to be holding up fine. Krylon Fusion needs no primer and bonds really well. For a smooth finish, paint a coat, let cure, sand with 600 wet or dry and repeat until You're satisfied, as it seems to be a high build product that will sand very well.

Heres a pic of my XJ:



I painted them and slapped them on, but they could use fine sanded with 1000 wet or dry and polished then waxed but I'll get to that when the Eleven is on the road and I can take the XJ apart for a full resto.

[ddragon63]

Drill a small hole @ the stopping point of the crack to stop its run. They make a plastic body filler (auto usage) that is very flexible you could try. Back it with something fill the area and sand it down. JAT

[psycoreefer]

I put a single layer of thin fiberglass with some epoxy resin on the back of my 'cracked' side cover and I've been using it daily for 2 years now and its still holding on nice and strong. Once the fiberglass was dry I used a soldering iron to melt the crack back together and then filled with several layers of filler primer. I can take some pictures when I get home....