How to Repair ABS Motorcycle Fairing?

Last Updated: January 14th, 20211432 words

No matter how you baby your motorcycle, it will eventually get hurt because of those unpredictable accidents.

Somehow you will have to figure out how to repair abs motorcycle fairing when it’s not badly damaged, like:

  • Small Cracks
  • Broken tabs
  • Missing area

In this post, you will know how you could spend less than $50 by using PlastiFix to get them fixed.

So please don’t discard your fairing and do the best to repair them.

Let’s go ahead.

Repair the small cracks on fairings

Instead of reading the text, you could watch the above video as well:

  • Prepare for the repair by transferring the PlastiFix liquid into the applicator bottle.
  • Unscrew the top from the applicator bottle. Push the tip sideways until it breaks free.
  • Use the pipette that was included with your PlastiFix kit to transfer the liquid to the applicator bottle.
  • Continue until the applicator bottle is full.
  • When the bottle is full, replace the tip by snapping it into place.
  • Install the needle onto the applicator bottle by pressing it onto the tip, then remove the needle cover.
  • Remove the tip from the powder bottle and fill the dispensing cup with powder.

Do your best to remove these contaminants by using the Super Clean, which is a mild solvent based cleaner.

Use the clean cloth or paper towel to wipe the damaged area in one direction, in order to avoid re-contaminating the surface.

Use a rotary tool with a teardrop shaped cutting bit and grind about halfway through some of the plastic along the crack line. Be sure to round off any sharp edges.

As this line is where the PlastiFix will be applied, the surface will be flush with the surrounding plastic.

  • Squeeze two or three drops of liquid into the powder, then use the tip of the needle to stab the ball of liquid and powder.
  • The hole of the needle is on the side of the needle, not at the tip.
  • When you transfer the ball of liquid and powder to the crack, give the bottle another squeeze.
  • The liquid will run down the side of the needle and wash off the ball.
  • Continue using this method until the crack is filled with PlastiFix.
  • Allow PlastiFix to cure fully before working on the opposite side.

Just as you did on the opposite side, fill the v-groove line with PlastiFix and allow PlastiFix to cure fully.

Use a rotary tool with a teardrop shaped cutting bit and remove any excess PlastiFix until the level of the PlastiFix is slightly below the level of the surrounding plastic.

  • Allow the filler to cure fully before sanding.
  • Sand the filler to the correct contour and finish sanding with 320 grit sandpaper.
  • Sand any area where primer will be applied with 320 grit sandpaper.
  • Tight spots may need to be sanded by hand.

With 320 grit sandpaper, sand the primer until the entire part has a smooth finish that is ready for a topcoat.

Apply the topcoat according to the paint manufacturer’s recommendation.

That’s it and you’re done.

Repair the broken tabs on fairings

Your original motorcycle fairings are often discarded because of the broken tabs and bolt holes. You just can’t hook them on the bike frame without tabs.

Well, by using the PlastiFix, you could copy an existing tab with the molding bar and recreate the missing tab there.

Instead of reading the text, you could watch the video as well:

  • Drop the molding bar into boiling water. Or heat the water in a microwave, it takes just a few minutes.
  • Allow enough time for the heat to soften the molding bar all the way through.
  • Remove the molding bar from the boiling water and it will be liable for a short time.
  • While the molding bar is still pliable, form the molding bar around the tab that you will be copying. This must be done quickly before the molding bar hardens.
  • Allow time for the molding bar pattern to solidify, then remove the pattern of the tab and set it aside.
  • Remove as much paint as possible, as PlastiFix does not bond well to a shiny surface.
  • Blow the dust away with compressed air.
  • Get the pattern that was created earlier and decide on the best location for the tab, and then tape the pattern into place.
  • This may be a little bit difficult, and you may need to get a screwdriver or something to aid in the removal.
  • You may need to fill in some voids that were not filled while the pattern was in place.
  • Again, allow time for the PlastiFix to cure fully.
  • Use a rotary tool with a teardrop shaped cutting bit to shape the tab and re-drill the bolt hole.
  • Grind away excess PlastiFix so that the thickness of the tab closely matches the thickness of the tab that was copied. PlastiFix can also be sanded if necessary.

You should now have a strong tab that closely resembles the tab that was copied.

Repair the missing pieces on fairings

If you got any missing piece on the motorcycle bodywork, no worry, you could create one by PlastiFix as well.

Instead of reading the text, you could watch the video as well:

  • Prepare for the repair by transferring the PlastiFix liquid into the applicator bottle.
  • Use a rotary tool with a teardrop shaped cutting bit to remove the paint where the PlastiFix will be applied.
  • Grind away some of the plastic so that after the PlastiFix is applied, the surface will be flush with the surrounding plastic.
  • Apply aluminium body tape to the backside, and use a body spreader to get a good seal of the tape to the plastic.
  • Use the body spreader to help put a small bend in the edge of the tape. This will help keep the PlastiFix contained.
  • It helps to get the piece as horizontal as possible to keep the powder from running off of the area.
  • After the powder is applied, squeeze the liquid applicator bottle to apply the liquid on top of the powder until the powder is saturated.
  • Continue layering the powder and liquid until the desired thickness is achieved.
  • Allow PlastiFix to cure fully before removing the aluminium body tape.
  • We are going to create additional strength to the repair with fibreglass tape.
  • Cut a piece of fiberglass drywall tape that will fit the repair area, and press the tape into place.
  • Just as was done on the opposite side, layer the powder and liquid until the desired thickness is achieved.
  • Allow the PlastiFix to cure fully.
  • The PlastiFix will be rough and will need to be shaped and contoured.
  • A pencil and ruler will assist with grinding to the proper shape.
  • Use die grinders and sanders to reshape the PlastiFix to the proper shape.
  • Tape a piece of paper to the undamaged piece and use a pencil or a crayon to get a rubbing of the shape.
  • Cut the shape out of the paper and flip the paper over. This is the contour that we need to transfer to the damaged part.
  • Set the paper aside for now.
  • Use a DA sander with 180 grit sandpaper to smooth the transition from the paint into the damaged area.
  • Tape into place the shape that was cut earlier. This gives an idea of how much filler will need to be applied.
  • Mix and apply epoxy filler to the area until the height of the filler follows the contour of the paper
  • Allow time for the filler to cure fully and then sand the filler.
  • When the filler is fully cured, sand it smooth with 320 grit sandpaper.
  • You can see here that excess material has been built up and needs to be removed.
  • Use a high-speed die grinder with a cutting burr or a rotary tool with a teardrop shaped cutting bit to remove the excess repair material.
  • Continue removing the excess repair material until the desired thickness is achieved.
  • The thickness now closely matches the original thickness and is ready to prime and paint.
  • Sand any area where the primer will be applied with 320 grit sandpaper.
  • Apply a high build flexible primer surfacer and allow time for it to dry.
  • With 320 grit sandpaper, sand the primer until the entire part has a smooth finish that is ready for a topcoat.
  • Apply the topcoat according to the paint manufacturer’s recommendations.

Now It’s Your Turn

Buy the PlastiFix to repair your fairing now and have a try on your original fairing before ending up buying a complete new fairing.

Hope this post helps you a lot.

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