Plastic repair made easy

[Army86VFR750]

I had a fairing boss that broke, so I went to the local Advance Auto, and found Permatex PermaPoxy 5 Min. Plastic Weld. It bonds 99% of all plastics. I figured Permatex has always been quality stuff, so I picked some up. It worked great, set in about 3 minutes.

So I looked at my solo seat cover. It was missing a huge chunk, and I was curious. (hey, it was broke, whats the worst that could happen?) I took some heavy duty plastic shipping tape, put the smooth side out, and another on top (2 peices face to face), and laid a layer of the epoxy the same thickness in the missing spot. Within 5 mins, I removed it and a nice smooth surface was left. I set it in the sun for another 10 minutess, and it was hard and slightly flexible. I mixed another batch, and smoothed in the holes, and made a nice transition under the cover. 30 mins later, I set it on the bike, took a sharpie and ran a trim line. Took the Dremel tool, and there it was.

Not to be one to doubt my work, I held it by the repair and shook it; nothing. No cracks, give, or anything else. So...I decided to do a little more. I took more tape, and made to tab that fits in the slot on the rear fairing. A little trimming, and wow. Again, 1 hour later, and I picked it up by the tab. Great bond! I got brave, and rotated it upward, holding it by only the tab. At a 90* angle, it held just fine, butt pad and all.

A little fine sanding and filling, and a SWAG on white duplicolor paint, and ...
(the dark line is where I need to finish sand, just needs a few days to set up)

[drewl]

So the missing piece was fabricated out of epoxy?

[Army86VFR750]

Yep! For about 5 bucks. You can see in pic1 how big the piece was. I'll take more pics when I do the 2 side tabs.

[ralph66]

I like that its vary inventive, I like to see people do this kind of stuff, please post more pics soon.

[karazy]

Nice job. How hard was it to sand?

[Army86VFR750]

Thanks, it was pretty easy to sand with 320. Finish sand with 600, prime, sand with 800, paint, sand with 1000. You can polish or wet sand with 2000 to finish.