VFR plastic reconstruction

I have had my VFR 700 for a week now. Last weekend I started fixing the cracks and tabs on my bikes fairings.

The damage was basic for a 26 year old sportbike. Both fairing side panels were cracked and scraped Tabs were broken off. Some repairs were attempted by a previous owner usually with offsets and no reinforcement.. Both sides of the center section had the corners broken off. The back of the tailsection was glued back on using Popsicle sticks as reinforcement. :) I have worked on other 80's era Honda bikes and think the plastic must get brittle.

The technique that I have used in the past is to sand the area with 36 grit carbide paper and then spray glue the surface and stick on some carbon fiber reinforcement then paint on epoxy. I overlap the reinforcement generously. Usually just one layer of reinforcement sometimes two layers with overlap and offset. I then cover the wet area with rip stop nylon. Once cured I peel it off and I have a good base for a secondary layup. On the missing corner of the center fairing I taped over the outside with duct tape to act as a mold release. I then spray glued on a scrap of 1/4" foam. The foam acts as an outside mould. I then spray glued on some carbon and painted on epoxy.

Well that is where I am at right now.

Anybody want to view some photos?

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VFR700
New tires, rebuilding plastic. For now...

Anybody want to view some photos?

That, sir, is a silly question. Of course we want pics!

Sounds like a pretty intricate process. Pictures would be great!

Pic'ts would be great I am going to make parts like this into a new set :laughing6-hehe:


Gary

Attached Images

• [image: IMG_0002.JPG]

How is this.
This is the first layer on the left lower fairing.
[video: http://youtube.com/embed/5WmrcKASj7I?html5=1&fs=1]

Here is the left corner of the center fairing. I taped up the outside with duct tape. then glued the pink board onto the duct tape with spray glue, The inside of the fairing has been roughened up with 36 grit paper. I have added the composite material and then painted it with epoxy. It is curing at present.

I am using carbon fiber but fiberglass would work almost as well. I have a roll of carbon so that is what I use.
[image: Posted Image]
More later.

I rebuilt the broken plastic on my old Ninja with some thin ABS sheet, and ABS pipe glue. It worked well. You just need to make sure the plastic is raw & clean in the bonding areas.

For hairline cracks a little MEK applied with a Q-tip can do the trick just be careful 'cause it's nasty stuff. Too much will melt the plastic, and you don't want to breath it or get it on you. I've also used some super glue made for plastic with good results on minor cracks.

Gary
I would make a dam from pink board, cardboard or some thin plastic after grinding down the plastic. Then add some composite and cover it with rip stop nylon or dacron fabric. It is going to take a few applications to get it to smooth out. If I was not so cheap I would just find a new part.

I'll be posting more photos on my project as I can.

Pic'ts would be great I am going to make parts like this into a new set :laughing6-hehe:


Gary

Mbrane yes there are several ways of fixing plastic parts. I have built several large composite parts with carbon fiber so that is what use.

I have found that once cracks appear then they are likely to come back unless the part is made stiffer. I have chased cracks around if one part is made "too stiff" as it transfers the stress to the adjacent area. Too much reinforcement can be as bad as not enough.

What is your long term success with your method.

I rebuilt the broken plastic on my old Ninja with some thin ABS sheet, and ABS pipe glue. It worked well. You just need to make sure the plastic is raw & clean in the bonding areas.

For hairline cracks a little MEK applied with a Q-tip can do the trick just be careful 'cause it's nasty stuff. Too much will melt the plastic, and you don't want to breath it or get it on you. I've also used some super glue made for plastic with good results on minor cracks.

http://www.vfrdiscus...into-one-piece/