How to fill big broken plastic hole?

Discussion in 'The Garage' started by indr, Feb 14, 2014.

  1. indr

    indr .

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    #1
  2. sailah

    sailah Lampin' it

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    Use some mesh screen to back it. Fiberglass tape for strength. Bondo and paint.
    #2
  3. k-moe

    k-moe Long timer

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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.
    #3
  4. Beezer

    Beezer Long timer

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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.
    #4
  5. D.T.

    D.T. Difficult but useful

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    I just bought a big roll of black Gorilla tape!
    #5
  6. squish

    squish Out of the office.

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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
    #6
  7. b1pig

    b1pig Been here awhile

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    this is what i had to weld up on a ZX7
    [​IMG]

    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....
    [​IMG]



    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/?set=a.1233915724031.2032865.1113316232&type=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.
    #7
  8. ragtoplvr

    ragtoplvr Long timer

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  9. Switchblade315

    Switchblade315 Long timer

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    This. Plastic welding is easy.
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  10. MotoDaveL

    MotoDaveL Been here awhile

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    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.
    #10
  11. k-moe

    k-moe Long timer

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    Just my experience from 25 years of welding plastics.
    #11
  12. k-moe

    k-moe Long timer

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    #12
  13. kantuckid

    kantuckid Long timer

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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.
    #13