Fixing My KLR650 Shrouds

Discussion in 'The Garage' started by zoomzu, Jan 3, 2013.

  1. zoomzu

    zoomzu Been here awhile

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    So my friend starts talking about composites/carbon fiber stuff. So I get on-line and start looking at materials. I come across this blue hybrid carbon/kevlar cloth.:deal

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    My shrouds need fixing/replacing. At almost $200 a side.....fix them it is. Now that the overnight temp is in the 20's, good time to work on them.

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    I tape up the out side.
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    And fiberglass the inside.
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    On the other side I used a small piece of kevlar my friend gave me. That's the yellow stuff.
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    Since I'm not worried about weight or how it looks on the inside, I just slap it on. Just want to get structure back.
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    After some filling and sanding on the outside looks like I'm ready for the overlay.:clap
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    I do like the flat look though.
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    That's not going to happen. They are getting some cloth.
    So my buddy is going to help with the overlay, since he has been self teaching do's and do nots, and with alot of help from you fine inmates here. This is his road to learning/experimenting. Just a little light reading.:norton
    http://www.advrider.com/forums/showthread.php?t=828372
    This weekend should be the moment of overlay.
    #1
  2. therivermonster

    therivermonster Been here awhile

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    Sweet!! We'll be slangin' resin in no time. :D

    Edit: I actually just saw the pictures, Mike (no pics show up at work) and they look great! The FG and Kevlar seem to be holding those cracks together quite well. Once you filled the cracks from the outside, those babies look ready for some overlay.

    One thing that you could do before you start cutting into that beautiful fabric is to make a pattern out of an old bed sheet or similar large piece of drapable fabric. You'll want to take into account the wrap around the sides, and the hole in the middle. You'll probably want to wrap around all the edges about two inches in order to ensure that the fabric that is showing has good weave and no loose strands. We may also have to make reliefe cuts in the middle hole to get the fabric to lay nicely, but we can wait and see how well it wants to conform to the shape of the fairing.

    Nice pics btw. Keep em comming.

    I'm off to sewing class now... *THATS RIGHT! I SAID SEWING CLASS!!* :eek1
    #2
  3. zoomzu

    zoomzu Been here awhile

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    Getting ready to put some cloth on.
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    Slathered up the shroud with some epoxy to stick the cloth to.
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    Overlayed the cloth on had some problems getting the cloth to stick to the backside. Wanted to wrap over the edges. The cloth wouldn't stick with epoxy so we cut the cloth. I'm hoping to still get a smooth edge after all the epoxy sanding and clear coating. So far it's not too bad. In hind site I would've taped the cloth to the back, and after the first coat cured. I would have epxoied the back side.:doh
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    Here's after I trimmed them up after the first coat cure.
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    Here's a close up with a wet third coat. I still have a bunch of sanding to do to get them smooth. But they are starting to look pretty good.:thumb
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    #3
  4. zoomzu

    zoomzu Been here awhile

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    After the 3rd coat cured I did a little light sanding, to knock down some high points. immediately after I start sanding, I see blue. I'm sanding the Kevlar. I don't want to sand through the fabric so I keep it light.
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    I guess more coats to get some build up.:huh

    When I trimmed the ends I used a Air dia. grinder with a carbon cut off wheel. and a respirator.
    #4
  5. therivermonster

    therivermonster Been here awhile

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    Those are looking good, Mike. That Kevlar seems to be a bit of a trouble maker when it comes to cutting. To be honest, I'm not looking forward to cutting it myself.

    Keep the pics comming.
    #5
  6. bwalsh

    bwalsh UUU, UUU!!!

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    First, They turned out real nice!


    Second, It's a little late now but...

    The thing to do when using Kevlar is add one(or more) 6oz layer of FG cloth on top of the Kevlar for a final layer. Lay both(or however many you are using) pieces at the same time. When it dries you will never see the FG, just the Kevlar. Then you have some leeway for sanding/smoothing/polishing, etc.
    To do it now, you would have to sand the Kevlar for the new epoxy/FG to adhere. The problem with that, as you probably have already seen is, the Kevlar will start to fray.

    You may get by with ever so lightly hand sanding and applying a top layer of FG, if you choose to do so. It may also be very time consuming.

    Good luck! :freaky
    #6
  7. bwalsh

    bwalsh UUU, UUU!!!

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    Good scissors are the key! I have a pair of dressmakers scissors for cutting Kevlar. Similar to these...
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    They work but there are scissors specifically made for cutting Kevlar...
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    As always, never use them for cutting ANYTHING else.
    #7
  8. kubiak

    kubiak Long timer

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    nice job on the shrouds!
    #8
  9. zoomzu

    zoomzu Been here awhile

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    Thanks for the info, if there is a next time I'll try that. I don't think I will this time around.
    #9
  10. zoomzu

    zoomzu Been here awhile

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    I have some Clauss kevlar scissors. They work great.


    thanks, I have a bit more that I want to do. Make them all shiny.:D
    #10
  11. bwalsh

    bwalsh UUU, UUU!!!

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    I don't blame you. I wouldn't either. What you have will last a long time.


    The second pic was one I grabbed on line and were NOT Kevlar scissors. :baldy
    The Clauss scissors look like the hot ticket!
    #11
  12. zoomzu

    zoomzu Been here awhile

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    Ok, just about layered up, and I'll start sanding to get it smooth.
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    the thing I like about this cloth is one direction it reflects blue. In the other the carbon.
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    This is my trouble area. I may just leave this semi bumpy.
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    I think it will still look ok. Besides from 10' nobody will know anyway. It is a KLR, not one of those over priced bikes you're scared to get dirty.:wink:
    #12
  13. bwalsh

    bwalsh UUU, UUU!!!

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    They look great! Do you have a link for where you bought the material?
    #13
  14. zoomzu

    zoomzu Been here awhile

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    I bought the cloth on ebay, but you can also get it here.

    http://www.uscomposites.com/
    #14
  15. zoomzu

    zoomzu Been here awhile

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    I'm about 90% done sanding on one side.:clap

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    #15
  16. therivermonster

    therivermonster Been here awhile

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    Wow, Mike! It looks like you were able to get the one on the right pretty flat. That's gonna look sweet once you spray clear, sand, buff, and polish. I can't wait to see them on the bike.

    More pics, please! :D
    #16
  17. zoomzu

    zoomzu Been here awhile

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    So I rough sanded the shoud for clear coat.

    <iframe width="560" height="315" src="http://www.youtube.com/embed/AfGNwSFB80Y" frameborder="0" allowfullscreen></iframe>
    #17
  18. zoomzu

    zoomzu Been here awhile

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    I'm ready to clear coat the shrouds, but it's cold. So I decide to use a heat lamp and a halogen light to warm the part while curing.
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    I get the first coat of clear on. Looking pretty good.
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    Pressed for time and it being cold, I rush the coats of clear and get a lot of runs. I know more work for me but, at least I can sand and buff that out.
    I had to do a lot of running around so I turn off the lights and go. When I get back, they need lots of more curing before I can wet sand. So I turn the lights back on. This time I get the heat lamp too close. :huh Damn, :cry bubble and it's burnt. Oh, well chalk the one up to expience.:kboom I'm not got to fix it, at least not now. Too cold and I don't have a good space to do this kind of stuff while it is cold.
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    My friend thrivermonster suggested to put a sticker on it. I like that idea....for now.....
    #18
  19. zoomzu

    zoomzu Been here awhile

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    Wet sanding the runs out with 400grit then 800 fallowed by 1500.
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    Polished...I need to do more work on them, but....I'm good for now.:norton
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    The sun could've been better for pics.
    #19
  20. therivermonster

    therivermonster Been here awhile

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    They look awesome, Mike. Is the burnt part behind the crash bars? If it is, SCORE!! :D

    You did a great job, man!
    #20