What is the best tech for repairing cracked/broken fairings? - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 12 (permalink) Old 7-30-2010, 1:20 AM Thread Starter
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What is the best tech for repairing cracked/broken fairings?

I'm wondering what different options there are for fixing cracked, broken, scratched fairings (including the fasteners part). What teks have you guys done, how much did it cost, and how'd it turn out?

Please link any teks you know about, and/or put your instruction on here.


Thanks.
-L
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post #2 of 12 (permalink) Old 7-30-2010, 2:46 AM
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Re: What is the best tech for repairing cracked/broken fairings?

first off do you have all the broken pieces? can the pannel be off for a few days or do you need the bike?

how big is the break or crack?
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post #3 of 12 (permalink) Old 7-30-2010, 4:32 AM
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Re: What is the best tech for repairing cracked/broken fairings?

for cracks ive had some good results with acetone. epoxy can be used but ive never had an epoxy repair actually last. with acetone you can actually dissolve some ABS into it and use that mixture to build up missing chunks.


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post #4 of 12 (permalink) Old 7-30-2010, 10:06 AM
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Re: What is the best tech for repairing cracked/broken fairings?

the one and only thing you need to fix cracks, missing pieces, and broken mounting tabs:

PLASTEX
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post #5 of 12 (permalink) Old 7-30-2010, 4:50 PM
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Re: What is the best tech for repairing cracked/broken fairings?

the plastic on our bikes is abs and acatone is designed for desolving and molding plastic and abs is in that group if u have missing or broken pices you are replacing pure abs is hard to find but a slightly wearker one is readly avalible and cheap it just needs some stiffins placed in it. of all kids toys legos is made of abs plastic.
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post #6 of 12 (permalink) Old 7-30-2010, 5:27 PM
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Re: What is the best tech for repairing cracked/broken fairings?

https://www.ex-500.com/index.php/topic,22637.0.html
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post #7 of 12 (permalink) Old 7-30-2010, 6:48 PM
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Re: What is the best tech for repairing cracked/broken fairings?

in the link it talks aobut the plastic being soft and cuts easy that is due to not fully curred if i understand right it will take up to 10 days for all the solevent to evaporate out of the plastic and deff do not paint it next day or it will bubble up if its a big crack
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post #8 of 12 (permalink) Old 8-3-2010, 5:49 AM
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Re: What is the best tech for repairing cracked/broken fairings?

I dissolved some lego blocks in acetone. Used a dremal to clean up the crack and used a knife blade to fill the crack with the lego/acetone mix. After a week to let it dry and harden I sanded it back, masked and repainted.

I've used this method to reattach fairing stays as well. Fixed small holes same way but with a piece of cardboard behind the hole and layering the lego/acetone mix slowly to build it up.

Plastex has been recommended to me but over here Q-Bond is the equivalent. I'm using it to do some repairs on the GPZ900 fairing.


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post #9 of 12 (permalink) Old 8-3-2010, 5:06 PM
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Re: What is the best tech for repairing cracked/broken fairings?

waynemorgan said what i would have just be sure you give the part a few days to cure b4 paint it will take up to 10 days to fully cure
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post #10 of 12 (permalink) Old 8-19-2010, 11:55 PM
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Re: What is the best tech for repairing cracked/broken fairings?

Three things have worked incredibly well for me.

1: Duct tape
2: Streetfighter it
3: Put on different plastics.

'99 500R<br />-Custom bones<br />-'07 GSXR 750 shock<br />-Off brand Clip ons(below the clamp)<br />-'02 R6 subframe<br />-'01 ZX9 gas tank<br />-'06 ZX6 tail (hotbodies racing fairing, stock seat)<br />-'06 ZX6 front fender<br />-Yoshimura 2-1 exhaust<br />-UNI PODS (and it runs great!)
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post #11 of 12 (permalink) Old 10-24-2012, 9:09 AM
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Re: What is the best tech for repairing cracked/broken fairings?

They actually make an ABS Plastic welding kit. It melts ABS Plastic sticks.
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post #12 of 12 (permalink) Old 10-24-2012, 10:07 AM
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Re: What is the best tech for repairing cracked/broken fairings?

I use two soldering irons. A electric gun (quick heat on a small spot) and a large heavy iron.
Tack the pieces together with the gun, then fuze them solidly with the big iron.
You must melt all three pieces together at the same time. (The filler and the broken parts) It is essential to penetrate deeply. You must do both sides. Don't think for a moment you will not damage the paint, you will.
Subsequent work to build up the area can be finished as good as the original surface.

Acetone will not dissolve ABS
Any form of glue will take too long to harden and will continue to shrink for years Spoiling any paint over it.

I have a plastic welder but as of yet have not mastered the trick of using it. Amounts to a hair dryer with heated air focused to a small point, Tends to blow the melted plastic out of the joint.


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