Plastic Side Cover Repair

[cowboyup3371]

Today while putting the bike up on the centerstand to check the oil before a short ride, I absentmindedly put a knee into my left side cover and cracked it. While searching, I found a post on here referencing a website detailing how to repair it (http://sportbikeguy.com/garage/floor/plasticrepair.html). I already have a soldering iron and am tempted to try it but I don't know what I'd be looking for if I look around town for ABS.


Can someone give me some advice on where/what to look for when I look for ABS? I could melt down my kids' legos but I'm pretty sure they'd be mad at me for a LONG time.

How easy is it to do this repair or should I look for a left side cover?

How do I do the spot weld they are talking about?

[chuck hahn]

Look in search for PROJECT WINDJAMMER...the one where we sent Andre the fairing. Theres details about how to use ABS plastic shavings and acetone to do basically a chemical reweld of the plastic bits.

[cowboyup3371]

Yea, I started looking at Adler's repair but I'll keep looking on that site too. How much acetone do you use and are there any other precautions I should use as in certain types of containers etc?

[Nessism]

Another option is to use epoxy and fiberglass cloth on the backside of the crack. Flex the crack just enough to get some epoxy inside, then cut a 1" wide strip to reinforce the crack area. I've used this method on several cracked side covers and it works a treat.

[chuck hahn]

Get a metal tuna can style and use a rasp to grate a good handfull of shavings in it..then slowly add a little acetone till its about the consistency of thick school paste or thick epoxy. Then use some cotton balls and dip them in some acetone and dab it along the crack on the backside of the cover..this will make the cover a slimey sticky surface. Smear the prepared slurry along the crack kinda like a thickish patch. Let it sit out in the sun for a few days till the acetone evaporates out and youll have a solidly welded plastic repair. Sand it and repaint as needed.

[cowboyup3371]

Another option is to use epoxy and fiberglass cloth on the backside of the crack. Flex the crack just enough to get some epoxy inside, then cut a 1" wide strip to reinforce the crack area. I've used this method on several cracked side covers and it works a treat.

Would I put the epoxy on from the back?

[chuck hahn]

yes.. but if your gonna repaint it, you can do a iltte epoxy from the front too and sand it like it had never been cracked. Is it just a plain black cover or what?

[cowboyup3371]

No I repainted it last year so I'll need to do some sanding to remove the paint first. I was already planning on having my tank repainted later this winter but I didn't plan on this happening now. I'll probably try to fix the side cover now and not repaint it until later when I have the tank done.

[Dogma]

I have plenty of scrap ABS off the 3D printer. I even have some parts I'm not using that could be ground up to make some glue. PM if interested.

If you want your own stash, I think Harbor Freight has ABS plastic welding rod.

[Nessism]

Another option is to use epoxy and fiberglass cloth on the backside of the crack. Flex the crack just enough to get some epoxy inside, then cut a 1" wide strip to reinforce the crack area. I've used this method on several cracked side covers and it works a treat.

Would I put the epoxy on from the back?

Scott,

It doesn't matter what side, just spread the crack enough to get some glue inside. When the crack is pushed back together the excess will squish out. Clean off the excess on the outside surface that will show, and then laminate a strip of fiberglass cloth into the back side to reinforce the area. Hobby stores sell fiberglass cloth to reinforce R/C airplane wings. Only costs a few bucks. Make sure to sand down the plastic on the back side before you do the glass work as you want a solid surface to bond to.

[MisterCinders]

You can also salvage ABS shavings from any discarded plastic bits from your bike (e.g., some fenders, tool tray, etc. That assumes you have some spare plastic parts to begin with.

Or, just grab some LEGO blocks. They are made from ABS.

[Steve]

Another source for ABS is Lowe's, Home Depot or ACE Hardware.

Look for the black plastic pipes in the plumbing section, then look for one of the cheapest connectors and shave it up.

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