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Discussion Starter #82
I think so, I read somewhere that the clymer book was a lot better, it has all the uk specs as well as US and Canadian spec bikes. Hoping it will help when I attempt to put everything back together :rolleyes:
 

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Did you have that repaired Ian?
Yessir. The piece in my hand was from a damaged CRF450 engine case that my buddy made to fit the cleaned off position of the case. The tricky part was the potential loss of the mounting bolt hole, but wow, my buddy nailed it. Then I had a local welder weld it on.
107623
 

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Discussion Starter #84
That’s awesome, I love a functional repair. If only someone could do a similar repair on my front fairing!
 

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You could plastic weld with some MEK if you're feeling lucky, or you can use some fiberglass. I've had to do quite a bit of repairs on my fairings. It's a lot cheaper than a Chinese set.
 

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Discussion Starter #86
You could plastic weld with some MEK if you're feeling lucky, or you can use some fiberglass. I've had to do quite a bit of repairs on my fairings. It's a lot cheaper than a Chinese set.

I have spoken to a couple of well respected bodywork guys that specialise in bike fairings and the general consensus is that the damaged part would be too difficult to rebuild

107637
 

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Discussion Starter #87
Check the engine case as well as the side cover for cracks. If it’s been down on the left side it’s a good possibility. My 99 was missing a good chunk of engine case....... View attachment 107615
Managed to remove the generator cover today and I believe the complete lack of any gasket was the cause of the leak and not a cracked casing thank god!
107638
 

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I have spoken to a couple of well respected bodywork guys that specialise in bike fairings and the general consensus is that the damaged part would be too difficult to rebuild
Without disrespecting your bodywork guys, they might be looking at the 'repair' from a commercial perspective. At a labour rate of even £50 per hour, costs would be out of the park.
But looking at it from a practical and personal repair, it is more than possible. Will require multiple layering of fibreglass, hours of sanding and shaping, hole drilling, priming and painting. I guess it depends how much work you want to put into it; but you could even consider doing it as a job on the side and still bunging on a set of Chinese, thereby retaining all your OEM fairings.

All depends upon your emotional connection to the bike. ;)
 

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Discussion Starter #89
It’s all down to cost to be fair, if Chinese fairings looked good enough for £400 odd then I’d go for those but if I can repair the front cowl and get the paint work tatted up for £400 then I’d keep the OEM. If I go Chinese the tank will need the dent sorting and paint matching also so in for a few ££ either way.... I do not have the skills to Repair and paint the tank myself but could possibly repair the fairing And get a paint shop to do the rest
 

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Discussion Starter #90
Can I use fibreglass to repair plastic? I better get researching, you have given me hope Nigel :)
 

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difficult to rebuild
yeah, with that attitude.

yes, they repair plastic fairings with fiberglass all the time. the resin used in fiberglass is plastic. the glass just reinforces it. you'd use it here to give the repair backing and structure. then you could rill with polyester resin if you wanted or keep going with fiberglass.

honestly, painting is really easy, especially with solid colors. harbor freight had a coupon for a $9.99 spray gun so i thought i'd give it a try. as long as you use urethane paints, you won;t have a problem putting any 2k urethane clear over. they're all over amazon and ebay. you could also find a automotive paint supply store and buy single stage urethanes. it's incredibly easy to do it and i can't believe body shops can get away with the prices they charge. at the end, you just wet sand and buff the same way you polished the frame.
 

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Because it’s gone across the pepper pot holes, I’m wondering if it needs some reinforcement. If it were mine I think I would try and drill some holes into the plastic and secure it with some stainless pins and epoxy resin before using fibreglass. It would be a very fiddly job but at least you’ll end up with a more secure and permanent repair.
 

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Fiberglass is stronger than abs plastic. If the plastic didn't need reinforcement, the fiberglass won't either
 

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Discussion Starter #94
has anyone used plastex before? I see lots of fairing repairs using it especially to build up areas that are missing. Or am I best to try fibreglass?
 

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Yes used that, and it's great for small cracks , but you would have to buy a whole lot to do what you need, stay with the Fibre Glass and Resin as said its cheaper /stronger
 

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has anyone used plastex before? I see lots of fairing repairs using it especially to build up areas that are missing. . .
Plastex is good, but be very careful about which type you buy. This one, for instance, might not give the results you require:

107652
 

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Have a look at any markings inside the fairing to see if you can determine the plastic used. On the 954 the cowl is ABS, and the sides are PolyEthelene. (As an aside the PE is probably better at handling heat which is why the Chinese ABS need heat shields).
The polyethelene can be welded with a soldering iron and is easy to do.
The ABS can be melted with Acetone or MEK etc. You can buy powder and mix it with acetone to form a glue. Or sprinkle it on the acetone in the crack.I have done this with aluminium flyscreen to give it strength. Basically melted the flyscreen into the fairing with ABS. Its easier to do than you think.
 

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. . . You can buy powder and mix it with acetone to form a glue. Or sprinkle it on the acetone in the crack.I have done this with aluminium flyscreen to give it strength. Basically melted the flyscreen into the fairing with ABS. Its easier to do than you think.
A friend has done this on another forum, with success. He'd kept a couple of trashed fairing and cut them up and ground them into powder for such a repair.

Not sure if he used his wife's kitchen blender though. I wouldn't be fancying the next chocolate cake!! :eek:
 

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Discussion Starter #99
I have replaced the generator gasket today and polished the cover, I painted the water pump cover and it’s looking good. The engine itself is pretty corroded and it seems a shame to have shiny new looking parts bolted to it. Has anyone ever had the corrosion soda blasted? I’ve had a go with various wire brushes etc but it still looks terrible
 
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