Another Project. - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 3 (permalink) Old 7-31-2019, 1:40 PM Thread Starter
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Location: Lisle, IL
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Talking Another Project.

I am always keen to learn to undertake repairs and restoration on all aspects on my bikes and cars. Mechanical repairs are relatively straightforward compared to those involving bodywork and paint.

My VFR is is need of small cosmetic attention at the base of the fairing, where crap from the front wheel bombards the chin of the fairings on a regular basis. Before I embark on the real project, I wanted some training practice. I found the ideal candidates on CL in the form of a sad bunch of nearly complete ZX-7R plastics. Everything from scratches, cracks, holes and broken parts....the full gamut to practice on. And the best part is the price....FREE.

I'm going to have plenty of material to practice with. I am planning to try a few methods of repair....fiberglass, plastic fill with liquid monomer and acrylic powder, etc. After that, a chance to practice laying filler, then primer, base coat and clear.


















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2007 Kawasaki EX-500 Ninja
2003 Honda Goldwing
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
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post #2 of 3 (permalink) Old 7-31-2019, 4:06 PM
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I've had good luck plastic welding ABS with a soldering iron and chisel tip. Tack the piece in the correct position and melt the crack together in a "welding" motion - pushing the tip into the plastic and almost through the other side, then flattening the ridges on the sides to fill the notch while it's still melted.

Having some filler is handy, and I've successfully used LEGO blocks (matched the red on my Honda CRF150 bodywork) as filler rod. Long thin pieces are the easiest to use.

After getting the backside side stitched, go back on the front side and join any open areas. You can use the tip to smooth-out and flatten rough areas after it cools also. Some ABS-compatible filler may be required on the top side after light grinding for adhesion and to get a low repair area.

Repair of a broken tab on the backside of the CRF shroud -


Last edited by jkv357; 7-31-2019 at 4:08 PM.
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post #3 of 3 (permalink) Old 7-31-2019, 4:16 PM Thread Starter
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I've heard about the melted lego trick before, and this can be another method I can experiment with. The method I saw mentioned melting the bricks down into a soup using acetone, which then was used as plastic filler. I think this is similar to liquid monomer and acrylic powder.

For dirt bike plastics which are extremely flexible, I have had great success with "Goop". Silly name, awesome product.

2007 Kawasaki EX-500 Ninja
2003 Honda Goldwing
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
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