How to Repair the Plastic Fairings on a Motorcycle

Modern motorcycles contain some bewilderingly high-end technology and precision components, engineered to within thousandths of a millimeter. They feature digital ignition systems and fuel injection, all controlled by blisteringly fast computerized brains. But the fairing, the colorful plastic shell that surrounds all this, can be one of the most staggeringly expensive components you may ever need to replace on your two-wheeled friend. The stinging irony will be familiar to anyone who has ever received a bill for a replacement fairing that threatened to exceed the value of the rest of their bike.

Instructions

1

Clear a space to work in that can easily accommodate all of your cracked and broken fairing. You'll want to lay it down as flat as possible, paint side down, as the plastic weld can become runny once it is heated. You may struggle, as fairings tend to be anything but flat, but try and get the damaged part as close to your work surface as possible.

2

Use sand paper or a rotary tool to sand down the edges on either side of the break. A rotary tool is ideal for this, as it will allow you to sand each edge back at a slight angle, so that they form a 'V' when placed together. This gives the liquid plastic weld an area to flow into, which helps to focus its strength where it's needed.

3

Position the two pieces next to each other so that the two edges of the break are touching. Ensure that they will sit next to one another without any input from you. Use a soldering clamp, vice or weight to allow them to rest in exactly the right spot. It is almost impossible to hold everything steady enough by hand to get a strong weld.

4

Heat up your heat gun to the appropriate temperature, and melt some ABS plastic weld as a test. It should melt instantly and be malleable, but not too runny. Build up the heat gradually but not too hot, as the heat gun could do considerable damage to your fairing.

5

Place two spots of plastic weld at the extremities of the break, allow it to cool and harden, then check the positioning. If not perfect, sand it away and try again. Once you have it right, gently pump the liquid weld into the "V" carved earlier. Allow it to settle and harden, then check it for strength. Sand any excess weld down and you are ready for paint.