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Old 02-14-2014, 03:15 PM   #1
indr OP
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How to fill big broken plastic hole?



Is there any way to fill this big of a crack. It's on a rear side fairing. The plastic is ABS. I don't have the piece of broken plastic.

I've heard about Bondo being good for this, but how exactly would I go about applying it to make it stay put, and not fall through since the hole is so big?

Once filled, I'm planning on sanding, painting, and clear-coating the fairing aswell.
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Old 02-14-2014, 03:23 PM   #2
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Use some mesh screen to back it. Fiberglass tape for strength. Bondo and paint.
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Old 02-14-2014, 04:32 PM   #3
k-moe
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Get some black ABS sheet, cut, weld, sand, paint.

Or. Cut the same size hole in the other side, stick a light behind both, and call it custom.
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Old 02-14-2014, 04:51 PM   #4
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fiberglass cloth and black ABS glue.... several layers and a couple extra coats. does it have to look pretty? if so then weld, sand, paint.
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Old 02-14-2014, 05:40 PM   #5
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Talking

I just bought a big roll of black Gorilla tape!
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Old 02-16-2014, 11:18 PM   #6
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You can try and look for a busted up matching fender part. Cut the new part in the same size as the hole
And hot air weld it in.
Or get some abs sheet and use a hot air gun to form it into the right shape.
Put a piece of paper behind the hole, draw the outline of the hole. Transfer that shap to the abs only make it bigger to take in account the stretching to fit the profile.
Then hot air weld it. Use a little fiberglass mesh on the back side for some support
Some reinforced body filler to fill and smooth the small gaps
Prime and paint
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Old 02-17-2014, 03:31 AM   #7
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this is what i had to weld up on a ZX7


if you can get some ABS sheet and shape it with a welding shoe and a heat gun... you might be able to make the repair. but if you dont already have the tools, getting a replacement part might be cheaper for you. because you'll have to finish/fill/paint the repaired part.

this was the same panel after i was done... you'd never know....




this album has a lot of the photos of the repairs. i didn't have to do too much shaping. the hardest part i had to do was where the left panel was broken at the large air vent. i used more filler there.
https://www.facebook.com/media/set/?...1&l=2293e56788

the golden rule is this. the top repairs are only as good as the base repairs. the better job you do on the panel, the less filler... the better the repair will end up being and the less likely it will fail later.
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Old 02-17-2014, 03:36 AM   #8
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weld it

Cheap kit
http://www.harborfreight.com/plastic...ure-96464.html

Rods
http://www.harborfreight.com/50-piec...ods-41602.html

also need abs glue, they make abs pipe glue and there are lots of others.

Your local paint and body shop supply store will have a good selection.

Labor intensive

Takes practice. Not normally as strong unless reenforced.

Rod
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Old 02-17-2014, 02:03 PM   #9
Switchblade315
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Quote:
Originally Posted by k-moe View Post
Get some black ABS sheet, cut, weld, sand, paint.

Or. Cut the same size hole in the other side, stick a light behind both, and call it custom.
This. Plastic welding is easy.
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Old 02-17-2014, 04:41 PM   #10
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Quote:
Originally Posted by Switchblade315 View Post
This. Plastic welding is easy.
it is, I welded my KLX side panel after parking the bike forcefully and at speed against a tree. It wasnt ABS plastic but a crappy soldering iron and some shavings from other parts of the panel did the trick.

ABS is kind of nasty to breath in so wear a respirator.
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Old 02-17-2014, 07:59 PM   #11
k-moe
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Quote:
Originally Posted by ragtoplvr View Post
weld it

Cheap kit
http://www.harborfreight.com/plastic...ure-96464.html

Rods
http://www.harborfreight.com/50-piec...ods-41602.html

also need abs glue, When welding there is no glue required
Your local paint and body shop supply store will have a good selection.

Labor intensive Much less so than metalwork, and only slightly more work than prepping for paint

Takes practice. Not normally as strong unless reenforced. Actually a welded repair is usually stronger than the originel part, but you must be sure that you use the correct filler rod and amount of heat. Don't bake the plastic until it's brittle.

Rod
Just my experience from 25 years of welding plastics.
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Old 02-17-2014, 10:20 PM   #12
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Quote:
Originally Posted by Beezer View Post
fiberglass cloth and black ABS glue.... several layers and a couple extra coats. does it have to look pretty? if so then weld, sand, paint.
Just so I get this right:

1. Put fibreglass tape/cloth on one side of the hole to give it a backing so the ABS glue doesn't drip through.

2. Fill hole with ABS glue and give it shape as necessary.

3. ABS glue basically bonds to/fuses/becomes part of the plastic itself???

4. Sand it down to look nice.

5. Paint...

My primary question is #3. The ABS glue is basically liquid ABS plastic? Once it's fused, cured, sanded down, and painted, the fiber cloth can be removed from the other side, and the ABS glue part will stay?
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Old 02-18-2014, 08:01 PM   #13
k-moe
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A kit is a good way to get your feet wet without undue stress.

http://plasti-mend.com
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Old 02-27-2014, 01:19 PM   #14
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you need a piece of the same plastic to weld with

take a weller soldering iron & use the "paddle shaped" tip

have a btl of spray water close by to "set" the hot welds

Puddle weld in the piece of plastic you cut to fill the hole. Tin snips are used to cut a "welding rod" for filler

good technique is to tack some spots then finish off the whole weld-also clamps may help initial positioning

some same marked plastic(read the letters on the old part) will give you much free material-get a broken one free from nearest car salvage place or AB shop

it works & much cheaper than glue or kits or HF plastic welders.
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