I love posting pics of progress!! Spent the entire day playing with plastics. Sanded down the gas tank and all fairings except for the front fender (D'oh!!).
Once daylight was gone, I sat down to repair the fairings. I used the same approach to fixing these plastics as I do when fixing interior plastics in the aircraft I work on (motorcycle plastics are a lot easier to work with). Anyway, I figure I'd give a little How-to on my way to fix cracks in plastic.
You will need-
-bottle of super glue
-bottle of super glue accelerator
-180 grit (or rougher) sandpaper
First off, clean/degrease the area, you do not want any grease or oil to contaminate the patch otherwise the end result will not be satisfactory.
Sand the area around the crack. Get it nice and etched, and usually sand an area about 4" wide and twice the length of the crack.
Then cut out about a 1 inch by 2 inch patch of fiberglass and lay it out where it needs to go, then trace around the patch. Remove fiberglass patch for now.
Lay down a bed of superglue for the fiberglass to attach to (you don't have to stay in the lines this time
Then set the fiberglass patch onto the bed of super glue-
Now, with the saran wrap, wrap your finger in it to massage the fiberglass into the superglue. You will be able to tell when the fiberglass is saturated.
Then spray the entire area with the super glue accelerator. This is the stuff I use-
And you're done! The trick is in the accelerator. It creates an exothermic reaction which flash bonds the fiberglass/super glue to the plastic. The results are tough as nails when done properly (the key is in the prep, and accelerator).
Here is what it should look like in the end. Semi-translucent. If it appears white then it did not get a good bond and already lifted away.
I also patched over the passenger grab rail holes