Fixing broken fiberglass

[Pearldrummer7]

Not on my 818, but I crashed my track bike last weekend and decided to repair the fiberglass myself. I'd like to show it off and provide a little bit of a guide, as I could've used one before doing this myself. I assume that if it I ever break the 818's body, I'll be doing some repairs myself.

First up, the broken:
https://c5.staticflickr.com/8/7409/27400040796_b1eaf6cf1f_c.jpg (https://flic.kr/p/HKfnwu)
https://c3.staticflickr.com/8/7358/27400040866_2290b94afa_c.jpg (https://flic.kr/p/HKfnxG)

Set up:
https://c7.staticflickr.com/8/7399/27157502830_f39be0ae8d_c.jpg (https://flic.kr/p/HnPirq)
https://c6.staticflickr.com/8/7675/26826759133_6a87c4ff55_c.jpg (https://flic.kr/p/GSA9RT)

[Pearldrummer7]

Some Bondo and woven fibers:
https://c7.staticflickr.com/8/7021/27400041726_97ce07792b_c.jpg (https://flic.kr/p/HKfnNw)
https://c3.staticflickr.com/8/7584/27157502970_78e98fa6ab_c.jpg (https://flic.kr/p/HnPitQ)

I basically pressed the resin and mixed fibers against the tape lines I made, which came out okay. Then I sanded with 40 and 60 grit and did it from the other side. Lots of elbow grease involved in this.
https://c5.staticflickr.com/8/7018/27400042116_827986980a_c.jpg (https://flic.kr/p/HKfnVf)
https://c7.staticflickr.com/8/7414/27157503190_fa4fdc35d0_c.jpg (https://flic.kr/p/HnPixC)
https://c6.staticflickr.com/8/7436/27362213141_74370aa067_c.jpg (https://flic.kr/p/HFUuFx)

[Pearldrummer7]

Affixed the two pieces together using a lot of fiberglass and then I held it for about an hour while it dried in the sun. I should've made a jig for this. It sucked.
https://c7.staticflickr.com/8/7447/27157504070_bf29222bc6_c.jpg (https://flic.kr/p/HnPiNN)
Then I added a few coats of paint with 400 grit wet sanding between!
https://c3.staticflickr.com/8/7221/26825174114_8450e1aa64_c.jpg (https://flic.kr/p/GSs2FY)

[Pearldrummer7]

So, the most important things are sanding and resin/bondo mixture, IMO. I use more hardener than recommended (by maybe 25%). It really limits how much you can do per concoction but it makes it easy to focus on one area and get it right; once it's right it'll stay and not sag or run at all.

Sanding sucks, but is important. :When you're done sanding, go back and do another hour" is the advice I got regarding it. Not that I have a perfect finish on it or anything, but it's a decent looking piece for just a bit of work every night for a 4 nights.

[Frank818]

Were you using those potato chips as a material or something, other than eating them? :)

Awesome work man! We see it is possible to repair a really damaged panel!
Sooo... how's the rest of the bike?

[UnhipPopano]

Here is my twin penny's worth of advice. Go buy a new fairing. Nothing negative about your project, but if you should sell the bike to make room for the car, you may have a hard time finding a buyer.

Also, remember to ware a face mask when sanding the fiberglass and resin.

[Frank818]

And what if he'll not sell it in a long while?

[wleehendrick]

Here is my twin penny's worth of advice. Go buy a new fairing. Nothing negative about your project, but if you should sell the bike to make room for the car, you may have a hard time finding a buyer.

It's a track bike; it looks looks just fine for that use, and it will probably go down again. If Frank decides to sell it, that's the time for a new fairing.

P.S. Do BBQ chips bond as well as Sour Cream and Onion?

[Pearldrummer7]

Were you using those potato chips as a material or something, other than eating them? :)

Awesome work man! We see it is possible to repair a really damaged panel!
Sooo... how's the rest of the bike?

Rest of the bike is okay! I had a broken support piece and it somehow killed the starter solenoid. Besides that...perfect :) I rode last weekend again.


Here is my twin penny's worth of advice. Go buy a new fairing. Nothing negative about your project, but if you should sell the bike to make room for the car, you may have a hard time finding a buyer.

Also, remember to ware a face mask when sanding the fiberglass and resin.


And what if he'll not sell it in a long while?


It's a track bike; it looks looks just fine for that use, and it will probably go down again. If Frank decides to sell it, that's the time for a new fairing.

P.S. Do BBQ chips bond as well as Sour Cream and Onion?

The bike has been through 4 owners at the track (that I know of) and each of them has been down multiple times on it. Easily 12 crashes so far, and I'll keep crashing on it for sure. The buyer is easy....I set a fast time around the track with it, and sell it at the track. New fairings are a lot of money!


And yes, I used a face mask for sure. That's some gross stuff! I use it while sanding too. Fiberglass just can't be good for the lungs.

Sour Cream and Onion chips (and beer) made this possible!

[mikeinatlanta]

Not to start a big debate:rolleyes:, but the glass fibers used in composites are generally considered too large in diameter to be respirable and not hazardous. Not saying the glass dust is good for you, but not as bad as sanding your drywall. Fiberglass insulation on the other hand...

[Pearldrummer7]

Not to start a big debate:rolleyes:, but the glass fibers used in composites are generally considered too large in diameter to be respirable and not hazardous. Not saying the glass dust is good for you, but not as bad as sanding your drywall. Fiberglass insulation on the other hand...

hm, good to know! I would've imagined the stuff I was sanding down was small enough to be an issue. But, it can't hurt to wear a mask anyway

[flynntuna]

Wear a mask, without one you'll be blowing your nose for a week to get all the dust out. Ask me how I know:rolleyes:

[mikeinatlanta]

hm, good to know! I would've imagined the stuff I was sanding down was small enough to be an issue. But, it can't hurt to wear a mask anyway
Imagine slicing a dowel into disks. They still can fit where the diameter is too big. I still agree that wearing a mask is a good (make that great) idea, just trying to put the risks into perspective.

Here is another one. Look at the MSDS for both denatured alcohol and acetone. Most look at the alcohol as safe and the acetone as dangerous. Not quite aligned with reality.