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Discussion in 'The Garage' started by indr, Feb 14, 2014.
Use some mesh screen to back it. Fiberglass tape for strength. Bondo and paint.
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.
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.
I just bought a big roll of black Gorilla tape!
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
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.
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.
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.
Takes practice. Not normally as strong unless reenforced.
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.
Just my experience from 25 years of welding plastics.
A kit is a good way to get your feet wet without undue stress.
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.