Broken fairing - repair ideas


Information and questions on GL1100 Goldwings (1980-1983)
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NKYWinger
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2003 GL1800

Broken fairing - repair ideas

Postby NKYWinger » Wed Feb 13, 2013 7:36 pm




Since I had the fairing off already, it's time to fix the hole from the PO.
My thought is to cut a sheet of 1/4" aluminum the conforms to the length and width of the whole bottom on that side. Since there is a fair amount of material missing, I do not believe that plastic or ABS will be strong enough. I will attach it to the bottom with a flexible adhesive.

Whatcha think?


--John--

FTCS(SS) USN Ret.
'83 GL1100 Aspy (SOLD)
'03 GL1800
'08 Lees-ure Lite
GWRRA 339547 KY - 'G'
DS# 1547

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Wilcoy02
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1983 GL1100I frame with an 80 engine. poor boy installed with C-5 ignition--DIED in Grande Prairie Alberta Canada 8/15


98 valkyrie sold 8/16

Re: Broken fairing - repair ideas

Postby Wilcoy02 » Wed Feb 13, 2013 9:51 pm

Get some black abs glue from home depot or lowes. ( do not use the combination of abs and pbs glue.) Mix some shavings from a black abs pipe into some abs glue.
Get some self sticking drywall tape.Or some fiberglass cloth. Either one works. The tape is less messy.

Put a coat of abs mix onto the crack from both sides. Place tape on both sides and then cover with the rest of the mixed shavings on both inside and outside. The abs glue will bond to the fairing. The mix will harden in 4-7 minutes so work it fast.
Do the outside and then mix and do the inside. This is sandable if not smooth.

I just did this to my lower fairings where the screw hole is at on both loweres. Hardens better than original.

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RoadRogue
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Re: Broken fairing - repair ideas

Postby RoadRogue » Wed Feb 13, 2013 9:56 pm

The whole fairing is made of ABS plastic. You can use ABS solvent cement to fuse the whole thing back together.

Step one is to "stop drill" all the cracks. 3/16" is plenty
I used a dremel tool to open up the cracks their entire length to ease any stress, this leaves a spider web of wide cracks that you can fill with ABS solvent cement.

I use masking tape on one side of the widened crack to give the solvent cement something to rest on while it dries . I also use a 10cc syringe to apply the solvent cement. This lets me push it all the way into the crack making sure the liquid make good contact with both sides without making a mess like just painting it on would. The glue will cure in about 24 hrs, it also shrinks. just add another layer to fill it up again and let it cure. repeat until the crack is over full.

The solvent cement is the same material as the fairing, its not just glued together, its welded andas strong as the day it was made. This is not a fast repair but it is the best repair. Any big missing pieces can be made from ABS plumbing pipe or sheet if you can find it.

You can sand the welds smooth , any dips can be filled with more ABS solvent cement and resanded once fully cured. Just remember that the thicker the crack , the more solvent cement it takes and therefore the longer it will take for it to fully cure. 8-)
Ride safe, Todd
Over night campers welcome

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NKYWinger
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Re: Broken fairing - repair ideas

Postby NKYWinger » Thu Feb 14, 2013 10:09 am

wilcoy & todd - I wish it were as simple as cracks! I guess my pic wasn't the best; there is a missing piece of the fairing about 4" by 6" that I have to fill in. If it were just cracks, I would do as you both have mentioned with ABS cement and shavings.
Since I have a large area to fill in, I need something solid, since the hold down studs are there. I don't want to have to remove all the electronics in the bottom of the fairing to be able to work on it and I though an aluminum plate would give me the strength I need - make sense?
--John--

FTCS(SS) USN Ret.
'83 GL1100 Aspy (SOLD)
'03 GL1800
'08 Lees-ure Lite
GWRRA 339547 KY - 'G'
DS# 1547

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WingAdmin
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Re: Broken fairing - repair ideas

Postby WingAdmin » Thu Feb 14, 2013 11:59 am

If you have an opening like that, get a piece of ABS, cut it to fit, and use the method described above to bond it in place. I've used this method before, and it works. The end result will be far stronger and resilient than trying to mechanically fasten a foreign substance like aluminum in place. I normally use a piece of ABS cut from ABS drain pipe bought at a local hardware store. Cut it in half lengthwise, heat it and flatten it. Then you can cut out the piece you need to use for your repair, make up some ABS slurry, and bond it in place. Use several layers of slurry (allowing to cure in between layers), and the finished repair will be stronger than it was originally when it came from the factory.

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Wilcoy02
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1983 GL1100I frame with an 80 engine. poor boy installed with C-5 ignition--DIED in Grande Prairie Alberta Canada 8/15


98 valkyrie sold 8/16

Re: Broken fairing - repair ideas

Postby Wilcoy02 » Fri Feb 15, 2013 1:18 am

+1 as wingadmin stated.
Do not try to use a foreign substance in this plastic. It will vibrate back out and wear the plastic away that you have left.
Use the method as he described. We both know you have a big hole there but this will be your best fix.

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NKYWinger
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Re: Broken fairing - repair ideas

Postby NKYWinger » Wed Feb 27, 2013 5:11 pm



Do to the large break in the ABS, I went ahead and made a repair plate out of 16 gauge aluminum. I fastened it in place with a high grade flexible adhesive. With some touch up work and a coat of paint, it should be relatively invisible...
--John--

FTCS(SS) USN Ret.
'83 GL1100 Aspy (SOLD)
'03 GL1800
'08 Lees-ure Lite
GWRRA 339547 KY - 'G'
DS# 1547

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littlebeaver
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Re: Broken fairing - repair ideas

Postby littlebeaver » Wed Feb 27, 2013 5:36 pm

Hey nice work.. That looks great...

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NKYWinger
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2003 GL1800

Re: Broken fairing - repair ideas

Postby NKYWinger » Wed Feb 27, 2013 5:43 pm

Thanks, beav!
Now that I've done the CBR coil mod and fixed the fairing, my wife has convinced me to do the HID headlight upgrade. She understands the "I didn't see him, officer" mind set....
--John--

FTCS(SS) USN Ret.
'83 GL1100 Aspy (SOLD)
'03 GL1800
'08 Lees-ure Lite
GWRRA 339547 KY - 'G'
DS# 1547

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littlebeaver
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Re: Broken fairing - repair ideas

Postby littlebeaver » Wed Feb 27, 2013 5:58 pm

Check out this guys ride...Pretty neat..


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Wilcoy02
Posts: 725
Joined: Sun Nov 21, 2010 11:37 pm
Location: Marengo, Ohio
Motorcycle: 1983 GL1100 I purchased 3/16

1983 GL1100I frame with an 80 engine. poor boy installed with C-5 ignition--DIED in Grande Prairie Alberta Canada 8/15


98 valkyrie sold 8/16

Re: Broken fairing - repair ideas

Postby Wilcoy02 » Wed Feb 27, 2013 6:46 pm

looking good. Now go out and enjoy the ride.

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NKYWinger
Posts: 344
Joined: Sun Oct 02, 2011 6:37 pm
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2003 GL1800

Re: Broken fairing - repair ideas

Postby NKYWinger » Wed Feb 27, 2013 7:12 pm

wilcoy- it's still in pieces all over the shop... gotta reassemble it first LOL


--John--

FTCS(SS) USN Ret.
'83 GL1100 Aspy (SOLD)
'03 GL1800
'08 Lees-ure Lite
GWRRA 339547 KY - 'G'
DS# 1547


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