Broken fairing - repair ideas

[KYWinger]

I had to take the fairing off to do some other work, so I need to address the broken bottom that happened from a PO. My thought is to cut a sheet of 1/4" aluminum to match the entire length of the broken pocket bottom.. This will give support on its entire length and be strong, light weight and rust free. I will hold it to the bottom of the fairing with some relatively flexible adhesive.

Can y'all think of a better solution? Since it's broken, I don't think any kind of ABS of plastic will give me the strength I need to make a durable, lasting repair...

 

[dan filipi]

Here's a post- Serious fairing repairs.

Whatcha think. Possible?

 

[KYWinger]

Dan - Since I don't have all the pieces, I'm not sure I could do that..PLUS I really REALLY don't want to gut the fairing :beg: ....you know how much crap is tucked in there! :sensored: ...
My needs are in the horizontal plane and load bearing, thus my thought on aluminum plate. Thanks for the idea, though :thanks: ...

 

[dan filipi]

I think your aluminum plate idea sounds good then but I'd use small bolts to hold it all together.
1/4" bolts with large fender washers on the inside seems good.

 

[KYWinger]

Dan - you read my mind....I'd just picked up a handful of big fender washers...

 

[dan filipi]

The fairing mount bolts on right there.
If you wanted to get a little fancy with it, pick up flat head screws and a step bit from Harbor Freight. The step bit makes recessing the screw heads flush real easy. That way you can bolt to as much solid plastic as you can and the screw heads won't interfere with the mounting bracket bolted to the aluminum plate.

https://www.harborfreight.com/3-piece-ti ... 69087.html
(Click for larger gallery image)

Harbor Freight step drill bit's

• dan filipi
• Feb 14, 2013

Not the greatest quality but they are inexpensive.
Better quality from Home Depot are $25 or so...

These are $10 for 3. Home Depot has much better quality but they are about $25 each.
I use them a lot so paying more for them to last is worth it.

 

[KYWinger]

Fairing repair

• KYWinger
• Feb 27, 2013

Due to the massive amount of missing ABS, I made a plate of 16 gauge aluminum and cemented it in...

Do to the large hole in the fairing, I went ahead and made a patch plate out of 16 gauge aluminum to cover the whole bottom side and attached it with a flexible adhesive. A little touch up work and some paint should make the repair almost invisible to the casual observer (I hope).

 

[dan filipi]

Looks good, John. Nice metal work!

 

[KYWinger]

Thanks, Dan :Egyptian: Now my wife has convinced me to do your HID headlight upgrade....it just NEVER ends... LOL

 

[backlander]

Nice work John.