Thanks for checking out my thread MrLamper! Glad you like it!

Finally fixed all the pictures... switched over to imgur

He lives in Cumbernauld, Glasgow but I know he'd be pretty miffed if he knew I'm not wanting to wait any longer. I only sent it to him because they quoted me on ebay about $70 to ship it... and he said, "That's too much, they are wanting to make extra $$ on the shipping, I'll send it for free so just have them send it to me." Didn't think I'd be waiting this long. I've known him for just about 10 years so this isn't like some random new friendship... oh well lol

Thank you for the very generous offer to help me out! 

That fender is likely ABS plastic, and most fiberglass has epoxy resin.

Epoxy is notoriously difficult, if not impossible, to adhere to ABS. I hate for you to spend a lot of time trying to get this just right and then deal with cracks or it literally falling apart.

You will be way better of starting with "plastic welding" technique to re-join the fender halves together to make a new whole fender. I skimmed this page but didn't read it in detail, however on first glance it seems to offer some pretty good information that applies to your fender:
http://faq.ninja250.org/wiki/Plastics_repair_with_ABS_cement

You will need some ABS cement, which may be hard to acquire (I can't find it locally), and a soldering iron, among other things.

If the joint were perfect you could probably use MEK to bond the two halves together but I think it's more likely you'll need some filler.

The type of plastic you are working with is critical as to which adhesive or filler will bond. I am 80% sure the Suzuki fenders are ABS, which is what most of this kind of bodywork is made from, but if it is PVC or acrylic or some polystyrene blend or whatever then you may have to pick a different adhesive. You'll know pretty quick because either the thing you use will work 100%, or it will absolutely not work.

FWIW I broke a tab off of a part of my Jeep when it was nearly new (the "door suround") and guessed that it was ABS, got some ABS cement and tried to glue it back. It was about as effective as sticking it together with chewing gum. In desperation I also tried epoxy, which just flaked off and didn't even leave a residue. I finally bought a new part, even though I had the perfectly matched cracked pieces. I just couldn't tell exactly what kind of material it was so I couldn't get the right type of adhesive/solvent/filler to do the job.

Cool info mr72!! I'll keep this in mind, totally.

I've had lots of success over the years messing with bumpers, fenders, plastics, fiberglass, etc. Dunno why I like working with stuff like this so much but I always have for some reason

He lives in Cumbernauld, Glasgow?!

Tell him someone on here called him a lazy scrote, and that he should get his arse to the bloody post office! Better yet, tell him an Edinburger called him a bampot for being such a lazy scrote.

Seriously, type "Cumbernauld" into this website and check how many Post Offices surround him. I'm utterly insulted that it has taken more than 4 months and he still hasn't shifted his lazy arse for you. What a scabby bawbag.

NO ONE IS THAT BUSY!

omfg I am so glad I wasn't drinking anything when I began to read your post!!! I woulda spit it all out on the computer screen from laughter lololololol I seriously can't stop giggling now XD XD

whooo I hafta wipe the tears from the corners of my eyes to check out that website rotfl     

Ugh my eyes hurt. Just went through and updated all the picture links. Dunno how long it'll last though...

I used a different method for plastic welding on my Katana tail piece mounts.



I believe it does depend on the type of ABS used, so I may have been lucky here, but it seemed to have worked.

Basically, I had the remains of an ABS mudguard I used on my 450 which I had to modify, so I cut bits of that up into little chunks and started soaking them in some acetone. After a while this makes a slurry. Keep it in an air tight container so the acetone doesn't evaporate and the ABS will begin to soften and eventually the slurry will form. As soon as you open the lid of the container, the acetone will start to evaporate allowing the slurry to start hardening, so use a bit at a time for what you're repairing. I used an old glass scented candle jar as the lid has a nice seal on it.





To do the repair, I cut some more ABS pieces to weld onto the broken tabs, and I used a soldering iron to drag across the joins deep enough for the ABS to melt and bond into the other side to hold it enough that I could then put the slurry on.



Then I added the slurry, working into the join as much as possible also.



All fixed...

I like the creative method using acetone!

That is absolutely rad, Pete! I love stuff like that.

I've never had much luck with plastic welding or things like that, but it seems like you know what you're doing. Good luck with your endeavors, ShowBiz

Maybe this might help when welding back together?

https://youtu.be/61iyLarL258

Chris

NICE Pete! I really enjoyed the pics... looks super strong for sure.

Thanks qc! I'm hoping to get something started this weekend.

And 63 I will be sure to check out that video asap.

Quick update on the hugger situation, just heard back from one of the people on ebay... I bought one for $63.17 total, including shipping (which is less than the original quoted me *just* for shipping). Can't wait to finallyyyyy get one 

They seem to be strong but only time will tell... gonna be a while until I get to really test them unfortunately.

That video looks handy but like he says, watch out for the fumes! The dissolving in acetone method is pretty smelly too, but probably not quite as harmful to your health...

Got my hugger already today right before I had to leave for work! So no pics of it yet but just figured I'd add that update.

I also got started on the front fender... haha all I did was measure and draw the line down the center of it LOL... I have company coming in from outta town tomorrow so projects are gonna have to be on hold (and I also had company last weekend when I said I wanted to really get started on the fender)... it's nice to have friends <3

Hey Showbiz, 2 questions:

1. When you painted the brake disk, is there still some flexibility provided by the buttons or is it now solid? (curious)

2. Your taillight looks great, did you use some sort of surround or something to blend it in? (want to copy like a total copycat!)

Chris

Howdy 63!
When I painted the front rotor, I spun/turned the buttons after the primer dried and then spun/turned them again after the gold paint was dry. I feel nothing abnormal or strange when I apply the front brake so I'm super glad about that.

The taillight is just an F style taillight I got off of ebay. It's a tight fit but it has been working well for me since I got it back in 2012. It came with the black rubber trim around the part that sits against the tail plastics. I'm glad you like it! The stock brick-looking one just wasn't doin' it for me looks-wise lol

Quote from: ShowBizWolf on January 13, 2017, 03:45:14 PM
Howdy 63!
When I painted the front rotor, I spun/turned the buttons after the primer dried and then spun/turned them again after the gold paint was dry. I feel nothing abnormal or strange when I apply the front brake so I'm super glad about that.

The taillight is just an F style taillight I got off of ebay. It's a tight fit but it has been working well for me since I got it back in 2012. It came with the black rubber trim around the part that sits against the tail plastics. I'm glad you like it! The stock brick-looking one just wasn't doin' it for me looks-wise lol

I think that rubber trim really sets it off. I'll have to keep my eyes peeled for my own one

Chris

Just searched real quick and here's an example of what I bought. Has the rubber trim seal thingy and the plug. Super easy!

http://www.ebay.com/itm/C015-2007-2008-2009-04-09-Suzuki-GS500-GS500F-Rear-Tail-Light-Brake-Back-Lens-/301865279419?fits=Model%3AGS500F&hash=item4648929fbb:g:lEUAAOSwFMZWtAJv&vxp=mtr

Test fitting the hugger! Looks like having the 140/80 tire is going to make this thing look nice... I'm thinking I don't want to do any trimming like the wiki post shows because of the bigger tire.

That looks so cool

Chris