how to: repair missing pieces in stock fairings

csideblue · 12-30-2005, 07:33 AM

tool/products needed:

orbital sander with 150grit sandpaper

rotary tool (dremel or equivalent)

soldering iron

120 / 400 grit sheet sandpaper

scissors

carpet knife

exacto knife

card stock (you can use a 3 x 5 notecard or any stiff paper)

pencil or pen

sheet of ABS plastic (the sheet below is about 22in x 16in x 1/8in thick, cost less than $5. i bought it from a custom display cabinet maker. this will last forever.)

i will be filling in one of the missing pieces off my rear cowl just below the mounting tab on the left.

let's begin, shall we*

1. trace an outline of missing area using cardstock.

2. cut out piece and place it on ABS sheet.

3. use exacto knife to trace outline of piece in ABS.

4. cut piece out with the carpet knife. DO NOT use the exacto knife to cut ABS, the blade is thin and may break off, it may also break off in your hand*

5. use sander to scuff area around the missing piece on the fairing, so you're not welding paint.

6. match it to the fairing. it doesn't have to be perfect.

7. use soldering iron and tack ABS piece into place. make a deep groove along the seams. go about 1/2-2/3 of the way through. use the soldering iron to fill in the groove and smooth it out as you go. weld a little outside the break to get a strong bond. let it cool for about 10mins. it should look like this.

8. do the inside as well for a stronger bond. use soldering iron to smooth the inside if you want but it's not neccessary.

9. use sander to knock of the high stuff.

10. use rotary tool to make edge flush.

11. use 120 and 400 by hand to blend in and smooth with surrounding area. now you're ready for primer/paint.

smooth as a gravy sammich*

post any questions/comments you may have.

.

csideblue · 12-30-2005, 07:36 AM

other missing sections getting repaired.

filled in and ready for sanding

[SIZE=3]before

[SIZE=3]after

.

falconfixer333 · 12-30-2005, 10:37 AM

This is being edited for content.. There is a place for this type of talk.. Thank you for your cooperation on this...

Edited by SHWELL (Board Admin), please PM me if you have any concerns...

qbnito537 · 12-30-2005, 05:18 PM

This guy is good! Very informative and the pics are perfect. Thanks

R1_Demon · 12-31-2005, 08:34 AM

Ali....thanks a bunch for posting this up. I hope this is placed as a sticky (I didn't check initially), but this kind of info is always welcome!!! I'm definitely going to have to try this sometime soon!

A couple of questions...what type of soldering iron did you use? Just the "straight iron" or a soldering gun? Any certain type of wattage needed?

Thanks again!

SHWELL · 12-31-2005, 10:17 AM

? I noticed some spidering starting, how is that handled.. I know that you repair is def going to slow it down, but exp tells me that it continues to spread.. Is there a small trick to incorporate to take care of that problem while making the repair??

csideblue · 12-31-2005, 01:07 PM

Quote:

Originally Posted by GSXR_Wizard

what type of soldering iron did you use?* Just the "straight iron" or a soldering gun?* Any certain type of wattage needed?

i use a regular old soldering gun. no certain wattage needed, just the kind that will get hot and melt plastic

Quote:

Originally Posted by Schwell

I noticed some spidering starting, how is that handled.. I know that you repair is def going to slow it down, but exp tells me that it continues to spread.. Is there a small trick to incorporate to take care of that problem while making the repair??

spidering is just the clearcoat cracking. once you start sandong it'll smooth out.

.

.

digidelia · 01-03-2006, 05:04 PM

i used abs cement to repair some cracks in my side fairings, but over time, i don't think it will hold up as well as this method would

good write up

ars0n750 · 01-04-2006, 01:43 PM

friggen awesome!

csideblue · 01-04-2006, 04:36 PM

Quote:

Originally Posted by digidelia

i used abs cement to repair some cracks in my side fairings, but over time, i don't think it will hold up as well as this method would

i used ABS cement when i first got into repairing plastics. it's good for filling in small cracks but when you have pieces that are separated then it gets messy. i find it hard to sand too.

.

digidelia · 01-04-2006, 05:28 PM

really? mine sanded pretty easily

csideblue · 01-05-2006, 12:40 AM

it sands easy but not even. like when i tried to feather a section, the ABS cement would come off in chunks instead of just sanding down smooth. i stopped using it after that.

.

csideblue · 03-16-2006, 06:37 AM

i have an whole new way of doing repairs now. it's much less time consuming. i'm trying it out today and see what's up.

12-30-2005, 07:33 AM	#1
csideblue AMA Racer Joined: Sep 2005 Posts: 236	tool/products needed: orbital sander with 150grit sandpaper rotary tool (dremel or equivalent) soldering iron 120 / 400 grit sheet sandpaper scissors carpet knife exacto knife card stock (you can use a 3 x 5 notecard or any stiff paper) pencil or pen sheet of ABS plastic (the sheet below is about 22in x 16in x 1/8in thick, cost less than $5. i bought it from a custom display cabinet maker. this will last forever.) i will be filling in one of the missing pieces off my rear cowl just below the mounting tab on the left. let's begin, shall we* 1. trace an outline of missing area using cardstock. 2. cut out piece and place it on ABS sheet. 3. use exacto knife to trace outline of piece in ABS. 4. cut piece out with the carpet knife. DO NOT use the exacto knife to cut ABS, the blade is thin and may break off, it may also break off in your hand* 5. use sander to scuff area around the missing piece on the fairing, so you're not welding paint. 6. match it to the fairing. it doesn't have to be perfect. 7. use soldering iron and tack ABS piece into place. make a deep groove along the seams. go about 1/2-2/3 of the way through. use the soldering iron to fill in the groove and smooth it out as you go. weld a little outside the break to get a strong bond. let it cool for about 10mins. it should look like this. 8. do the inside as well for a stronger bond. use soldering iron to smooth the inside if you want but it's not neccessary. 9. use sander to knock of the high stuff. 10. use rotary tool to make edge flush. 11. use 120 and 400 by hand to blend in and smooth with surrounding area. now you're ready for primer/paint. smooth as a gravy sammich* post any questions/comments you may have. . __________________ Ali - CCS Am #831 / WERA West Am #831<br /><br />need a bike painted? ... pm me for a quote/pics.

12-30-2005, 07:36 AM	#2
csideblue AMA Racer Joined: Sep 2005 Posts: 236	other missing sections getting repaired. filled in and ready for sanding [SIZE=3]before [SIZE=3]after . __________________ Ali - CCS Am #831 / WERA West Am #831<br /><br />need a bike painted? ... pm me for a quote/pics.

12-30-2005, 05:18 PM	#4
qbnito537 Superbike Racer Joined: Nov 2005 Posts: 438	This guy is good! Very informative and the pics are perfect. Thanks __________________ *Rick*<br />Asere!

01-03-2006, 05:04 PM	#8
digidelia Racing Junkie Joined: Sep 2005 Posts: 199	i used abs cement to repair some cracks in my side fairings, but over time, i don't think it will hold up as well as this method would good write up __________________ 2002 Suzuki SV650 - 2002 Impreza WRX Wagon<br /><br />Holy Jesus, what are these goddamn animals?

01-04-2006, 05:28 PM	#11
digidelia Racing Junkie Joined: Sep 2005 Posts: 199	really? mine sanded pretty easily __________________ 2002 Suzuki SV650 - 2002 Impreza WRX Wagon<br /><br />Holy Jesus, what are these goddamn animals?

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01-05-2006, 12:40 AM	#12
csideblue AMA Racer Joined: Sep 2005 Posts: 236	it sands easy but not even. like when i tried to feather a section, the ABS cement would come off in chunks instead of just sanding down smooth. i stopped using it after that. . __________________ Ali - CCS Am #831 / WERA West Am #831<br /><br />need a bike painted? ... pm me for a quote/pics.

03-16-2006, 06:37 AM	#13
csideblue AMA Racer Joined: Sep 2005 Posts: 236	i have an whole new way of doing repairs now. it's much less time consuming. i'm trying it out today and see what's up. __________________ Ali - CCS Am #831 / WERA West Am #831<br /><br />need a bike painted? ... pm me for a quote/pics.

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