Repairing some damage (largeish pictures)

[pave_spectre]

Due to a bout of severe frustration, my bike received a good kicking which resulted in some damage to the rear left fairing.

Can't stand  typical bodyfiller, so got hold of some ABS to make the repairs with.

First step was blocking in the big gaps with ABS sheet pieces.





Second step was filling in the remaining small gaps, and binding everything together with an ABS slurry.





In addition, I used the ABS slurry to reinforce the back side of the cracks that had been glued together but didn't require gap filling.


Next step will be to sand it to shape and prep for painting.

[fetor56]

Seems easier to make coffee and when u get frustrated simply smash the cup (AFTER drinking the coffee of-course)

[pave_spectre]

Wasn't a whole lot of coffee available, and the bike was being uncooperative in a moment of high stress.

[ShowBizWolf]

Interesting thread and cool pix of your work... I totally hear ya when it comes to getting frustrated sometimes.  I put a small dent in my gas tank with my fist last year because it just would NOT frickin line back up when I was reinstalling it   

[syntax_error]

I'm prone the break something in the moment of rage aswell. It always makes me feel like an @$$hole afterwards. Nice work on the repairs though. Sometimes Wayne Brady has to slap a ho

[pave_spectre]

Well I have managed to manufacture a replacement mounting tab.

You can see in the last image the kind of grey 3-shape from where the original snapped off.

It will probably be the last item attached to the fairing once it is all in position on the bike.

[pave_spectre]

Have started the sanding process.  Still a few high/low spots to deal with as can be seen here:




But I think it's near done, just need to finish up with the coarse grit and then move on to the finer stuff.


Also here's a pic of an original mounting pin:



And her's a pic of the one I am fabricating. Have already tested it for fit on the bike frame and it works well, is quite snug.

[pave_spectre]

Filling and shaping is finally complete.






Next step is to use finer grades of sandpaper to smooth the surface ready for paint.

[Suzuki Stevo]

Being a painter of complex aerospace parts (detail parts) now , I kinda the miss fit & file, sand & fill & the smell of fiberglass resin, Bondo & Evercote 

Be sure and post up some photos when you get it top coated   

[pave_spectre]

I have avoided the use of fibreglass, and bondo(or it's australian equivalent anyway).

I did have to use a skim coat of a grey solvent based putty in the end to fill in some of the fine imperfections that would have taken forever to sand away, but for the most part I have just used compatible plastic solvent welded into position. It will probably take me much longer to get to completion as I am only using a spare hour here or there on weekends.

[Blueknyt]

for ABs and many other plastics, if i cant glue em, i weld it back together useing a soldering Iron. it brings the strength back and doesnt require as much putty to pretty up if any. often you need some scrap parts to use as a filler, you can even buy plastic welder on ebay. some use compressed air, others use a heat gun with small nozzle or even like this one which is airless. http://www.ebay.com/itm/New-80-Watt-Iron-PLASTIC-WELDING-KIT-TPO-TEO-PP-Rod-Mesh-Auto-Car-Welder-/351121096661?pt=LH_DefaultDomain_0&hash=item51c072bfd5