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post #1 of 33 (permalink) Old 11-23-2005, 06:54 PM Thread Starter
 
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Repairing cracked plastics

Ok, so I wrecked my new R1 last week and am recovered enough physically to get to work on the bike. I took it out for a spin and it seems fine mechanically, but the plastics are cracked in a lot of places. All the broken places fit together beautifully, but I'm not sure how to bond them together. Will regular epoxy do the trick or is there a special bonding material I should use? I don't want it coming apart on me later when I'm on the road. I think I'm going to bring it in to a dealer just to make sure nothing is bent, but I think it's just cosmetic damage.

One more thing, do you all know anywhere I can get a new headlight and front fairing stay (the thing the computer attaches to) for cheaper than eBay? Only the left headlight is gone, but the bracket is twisted beyond repair. I would like to not have to spend $190 on the headlight unit and who knows how much on the bracket. Maybe if someone knows of a motorcycle junkyard in Central Florida? Thanks for any info!
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post #2 of 33 (permalink) Old 11-23-2005, 07:33 PM
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Canada... while I would like to hear more about your crash... this isn't the thread... maybe you can create another thread on that in everyday riding section... its always good to hear about crashes and what you've learned from it so that maybe a one of us can read about it and not do the same mistake... just a thought.

Second and most important... glad to hear you're ok.

Now to get down to biz...

Fixings those plastics...

Epoxy will definately help put it back together. I would get a nice 2 part epoxy and do a little at a time.

Another option.. a plastic welder. You can get them for cheap and then all you need is some time and a air compressor... 25 gal at least.

Spare parts....

Ebay is always going to be your best bet. However, you will find that these cosmetic parts while cheaper than buying from the dealer aren't going to be dirt cheap. Reason being... high demand!

You can also try PartsFish or Ron Ayers

Try MotoDirectory for some salvage yards. Looks like there is 5 of them in Florida.

Junk Yard Dog is another option. And it has 38 listed yards in Florida for motorcycles.

Hope it helps!!




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post #3 of 33 (permalink) Old 11-24-2005, 02:33 PM
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Quote:
Originally Posted by Gas Man
Canada... while I would like to hear more about your crash... this isn't the thread... maybe you can create another thread on that in everyday riding section... its always good to hear about crashes and what you've learned from it so that maybe a one of us can read about it and not do the same mistake... just a thought.

Second and most important... glad to hear you're ok.

Now to get down to biz...

Fixings those plastics...

Epoxy will definately help put it back together. I would get a nice 2 part epoxy and do a little at a time.

Another option.. a plastic welder. You can get them for cheap and then all you need is some time and a air compressor... 25 gal at least.

Spare parts....

Ebay is always going to be your best bet. However, you will find that these cosmetic parts while cheaper than buying from the dealer aren't going to be dirt cheap. Reason being... high demand!

You can also try PartsFish or Ron Ayers

Try MotoDirectory for some salvage yards. Looks like there is 5 of them in Florida.

Junk Yard Dog is another option. And it has 38 listed yards in Florida for motorcycles.

Hope it helps!!
with Gas Man. Its not hard to repair if you have all the parts. (no holes) You can fix them also with a welder but its a PITA. Yamaha has some of the cheapest body parts of all bikes. Look into getting new and/or used stuff. Remember after you get every thing fixed. You still have to paint it to look good.

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post #4 of 33 (permalink) Old 11-24-2005, 03:07 PM
 
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Quote:
Originally Posted by jeeps84
with Gas Man. Its not hard to repair if you have all the parts. (no holes) You can fix them also with a welder but its a PITA. Yamaha has some of the cheapest body parts of all bikes. Look into getting new and/or used stuff. Remember after you get every thing fixed. You still have to paint it to look good.




Might not be worth the time, energy, and money to repair (depending on the damage). If you have the money to replace, I would do that instead. Im still looking for a pair of decent yellow side fairings for my bike on Ebay. glad youre okay, and also glad that the bike seems like its okay mechanically.


You should post some pics of the bike so we know whats up with it....that being said

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post #5 of 33 (permalink) Old 11-24-2005, 07:13 PM
 
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Epoxy works great if you can clamp the pieces together, but on most fairings, you can't. At the motorcycle show last week, one vendor had an instant type of solvent glue. When the solvent dried (almost instantly), the plastic parts were welded (melted) together. Any hardware or hobby shop should have a similar solvent glue, but make sure it's for ABS plastic. For larger cracks, you can glue in a backing piece of similar ABS plastic or even some fiberglass cloth. Type in "ABS plastic repair" in google and see how many hits you get.
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post #6 of 33 (permalink) Old 11-24-2005, 07:31 PM
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Yeah I think is appropriate! Let's see how bad it is!




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post #7 of 33 (permalink) Old 11-24-2005, 08:05 PM Thread Starter
 
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ok, here's some pics....

after removing the fairings, computer, and bracket. there's a dent on the tank but the frame and engine seem ok. i didn't take one as it was before removing everything, but read on to see the damaged parts being repaired.



here's the front fairing stay....the bike went down on the left and must have smashed the left headlight pretty hard....bent the bracket as seen here, sheered off the left half of the headlight and broke the upper cowling.



notice the left part of the headlight in the background. that half is in great condition



ok, on to the repairs....here's my setup to hold the rear cowl together while the epoxy sets....





that part is setting right now and i'll work on attaching the rest of it tomorrow. after the epoxy sets, i'll back all the cracks with fiberglass mesh. i'll strip the paint off the whole rear cowl, sand it down smooth, prime and repaint. the upper cowl is going to be a bit harder.....i need to go back to the crash site and look for a little piece that outlines the left headlight....i remember seeing it but it didn't get picked up. this joint is so narrow, i'm gonna have to really reinforce it once the epoxy dries....



ok, that's all the pics for now. the headlight unit and fairing stay are the two most expensive problems, pieces i can't really fix. i'm going to try taking the bracket to a metal shop and see if they can straighten it out.
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post #8 of 33 (permalink) Old 11-24-2005, 10:44 PM
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Looks like a ton of work. Enjoy!

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post #9 of 33 (permalink) Old 11-25-2005, 12:05 AM
 
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Quote:
Originally Posted by No Worries
Epoxy works great if you can clamp the pieces together, but on most fairings, you can't.
Canadaman, you made me eat my words.
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post #10 of 33 (permalink) Old 11-25-2005, 10:51 AM
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Ya... it sure looks like you got it under control.... YOU GO!!!




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post #11 of 33 (permalink) Old 11-25-2005, 02:11 PM
 
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Quote:
Originally Posted by Gas Man
Ya... it sure looks like you got it under control.... YOU GO!!!

Probably not as much as you, but I am looking forward to the finished product!

with repairs!
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post #12 of 33 (permalink) Old 11-25-2005, 08:25 PM Thread Starter
 
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here's some more pics....

repairing the rear cowl...







and the finished product...









the shape is right on, and i'll be reinforcing the back side with fiberglass mesh soon.

these pieces all look to be in good shape...



here's the headlight unit up close....is there a way to just reinstall this one half and drive legally with it till i can afford a replacement?





some bad news....i went to the crash site and couldn't find the piece that fills in the gap here. i guess it's a new upper cowl for me



just a little prop for zero gravity, instead of cracking the windscreen, the screw heads sheared off....that made me happy



alright, that's it for now....thanks for the encouragement along the way....i'm just not looking forward to dumping the money for the new parts i know i need oh well, live and learn.
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post #13 of 33 (permalink) Old 11-25-2005, 09:10 PM
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it sure looks like you know what you're doing!

What color/paint are you thinking about after all the repairs?




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post #14 of 33 (permalink) Old 11-25-2005, 09:18 PM Thread Starter
 
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Quote:
it sure looks like you know what you're doing!
trust me, it's just an illusion i don't know about paint....the red/black scheme is what first caught my eye to this bike and i really like it. i'm sure i could get the color matched and repaint it the same. how expensive is a paint job on a bike? like if i were to repaint all the fairings? if i were to paint it any other way, i would want something along the lines of the 2003 special edition yamaha r6/r1, black with red flames. anyway, it all comes down to cost right now. i'm happy riding it around with just the primer for a while, no problem. i just want to get it back on the road!
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post #15 of 33 (permalink) Old 11-26-2005, 07:39 AM
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As long as you are not trying to color match a stock color it isn't bad. Show the painter what you want and let him do it. The stock Jap bike paint is only made by one company and only sold in, I believe, quarts.

Stock OE Jap bike paint = $$$$$$
Whatever paint a normal body shop has = $$ = not as bad!




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post #16 of 33 (permalink) Old 11-26-2005, 09:21 PM
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Quote:
Originally Posted by Gas Man
As long as you are not trying to color match a stock color it isn't bad. Show the painter what you want and let him do it. The stock Jap bike paint is only made by one company and only sold in, I believe, quarts.

Stock OE Jap bike paint = $$$$$$
Whatever paint a normal body shop has = $$ = not as bad!
on this one. Also, solid colors will be cheaper.
Price will vary from shop to shop. It depends on how good you really want it in the end. With out knowing your area. I would guess it will cost you some were around a few hundred for a basic cheap job to several thousand for fancy custom show quality work.
The last bike I paid to be painted one color (normal body shop collision repair quality) cost me $600.

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post #17 of 33 (permalink) Old 11-27-2005, 01:01 AM Thread Starter
 
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anybody painted themselves? i don't have an air compressor for a paint gun. what about rattle cans? i certainly don't care about show quality, but i do want it to look good and stay on the bike at the occasional 130+ MPH. anybody's experience/advice would be appreciated.
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post #18 of 33 (permalink) Old 11-27-2005, 10:20 AM
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Quote:
Originally Posted by canadaman123
anybody painted themselves? i don't have an air compressor for a paint gun. what about rattle cans? i certainly don't care about show quality, but i do want it to look good and stay on the bike at the occasional 130+ MPH. anybody's experience/advice would be appreciated.
I have seen some rattle can jobs that actually didn't look like total A$$ when complete. Unfortunately most do. It takes just as much prep as doing it with the right equipment. Then you will pay around $5 a can for decent paint. (2 to 3 cans per piece). I would just find a budget paint shop and let them do it for a few hundred or less.

As for the headlight, Does it have high and low beam both on the good side. I cant remember. If so, you may be able to slip by with out the other.

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post #19 of 33 (permalink) Old 11-27-2005, 12:04 PM Thread Starter
 
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Quote:
As for the headlight, Does it have high and low beam both on the good side. I cant remember. If so, you may be able to slip by with out the other.
yes, the right headlight is the only one that did turn on with the highbeam and they both were on for low beam. should i do something to fill in the open hole on the left side till i get a new headlight unit?
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post #20 of 33 (permalink) Old 11-27-2005, 12:40 PM
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Quote:
Originally Posted by canadaman123
yes, the right headlight is the only one that did turn on with the highbeam and they both were on for low beam. should i do something to fill in the open hole on the left side till i get a new headlight unit?
Not if you plan on actually fixing it later.

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