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1Back to top Go down   fairing repair Empty fairing repair Tue Dec 01, 2015 6:14 pm

1990k75

1990k75
Silver member
Silver member
So, wondering about the best way to repair minor damage to the K75 fairing...

It's fiberglass - but not mat, just 'rovings' ?

Let's see if I can upload a pic...

fairing repair Img_0410


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

2Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 6:24 pm

1990k75

1990k75
Silver member
Silver member
OK, so the pic worked - yay!

Now, is it realistic to repair this in place - or should I go through the whole process of removing that part?  Question 

And, what's the best way to repair this? - crazy glue, resin, JB weld... & then body filler & much sandpaper?

I'm sure many of you have been through this before, so bring on the wisdom.

Cheers, Lorne & Joanie


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

3Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 6:38 pm

Point-Seven-five

Point-Seven-five
Life time member
Life time member
The fairing is made from bulk molding compound.  It is a mix of glass strands in a putty of resin and filler material, probably talc.  It is put in a mold and heated which causes the resin molecules to crosslink and thus, solidify.  It's how the agitator in your washing machine is made.

As far as repair, I would straighten things as much as possible and saturate the fractures with Polyester resin.  Rough shape with 80 grit front and back.  Reinforce with a couple layers of resin and fiberglass mat applied to the back side.   Fill the surface imperfections on the front side with a polyester based filler.  Rough shape with 80 grit and final shape with 150.  fill scratches with a filler sanded with 220 followed by 320.

Prime and paint.


__________________________________________________
Present: 1991 K100RS "Moby Brick Too"
 
Past:
1994 K75RT "Ilsa, She Wolf of the SS"
1988 K100RS SE "Special Ed"
1994 K75S "Cheetos"
1992 K100RS "Moby Brick" R.I.P.
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

4Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 6:41 pm

Point-Seven-five

Point-Seven-five
Life time member
Life time member
No way you'll make a decent repair with the part on the bike.  you will be working with some messy stuff and need to get at the back of the part.  It really isn't all that hard to remove that part.  about 10 screws and a couple 6mm bolts hold it on.  You can leave the main fairing and the radiator grille.


__________________________________________________
Present: 1991 K100RS "Moby Brick Too"
 
Past:
1994 K75RT "Ilsa, She Wolf of the SS"
1988 K100RS SE "Special Ed"
1994 K75S "Cheetos"
1992 K100RS "Moby Brick" R.I.P.
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

5Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 6:50 pm

92KK 84WW Olaf

avatar
Life time member
Life time member
Lorne, that panel comes off very easy. So much nicer to be able to repair it inside in the comfort of home with a beer on the table.

From memory........I have done it so often and when you get used to it only takes about 10 minutes.

1. Open the left side storage box and you see 2 screws to front, 2 on left and also 1 each side of the lock mechanism. Take them all out. There is a metal support frame with 4 crosshead screws but you can leave it in place.

2. Bottom of the leg panel, not far from your left toe when its on the footrest there is another screw. Out with that one too.

3. You can now lift out the storage box and the left leg panel. The 2 screws between the box and leg panel often stay in but the box and leg panel will come out together

4. Under the storage box there should be a closure piece about a foot long, closing space between the fairing and the gas tank. Three screws in this. Out them too.

5. At the rear of that panel there is also a closure panel, about 6 x 3 inches, closes the gap between the side of fairing vent panel you want to remove and the air box. 2 screws and off with this too.

6. Now at last you can remove this panel, its got 2 screws at the front, when you look at the radiator straight on, from the front you will see a screw top and bottom facing toward the forks. Out with them.
You now need a 10mm socket and from where your left leg would be there are 2 mountings, with 10mm bolts and various washers. Out with the bolts, hold on to the damaged panel as these are the last 2 fixings.

Now you can assess it but I figure get a spare and sort it out, they are cheap as most get damaged at some point.

For me its filler such as Isopon, wet and dry rub down, primer, more wet and dry, paint etc. They are made of fiberglass and have a bit of weight.

The little downward leg on those vent panels on my RT were painted black. I think that's a very good idea as they get scuffed and it saves repainting the whole panel. In that location its not easy to see the quality of the painting so it can cover up a less than perfect repair.

Now to do the job you need fairing repair 905546712 :-c: Surprised-o:


__________________________________________________
1992 K100LT 0193214 Bertha Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red 578 bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 689 58,645 now 106,950 miles Deceased.
1983 K100RS 0011157 Fricka 606 Alaska Blue 29,495 miles Damn K Pox Its a Bat outta Hell Now 58,200 miles. 
1996 K1100LT 0233004 Lohengrin Mystic Red 38,000 miles currently 48,061 miles.
1983 K100RS 0004449 Odette R100 colours 58,000 miles. Sprint fairing now 61,190 miles

Past:
1968 Yamaha 80 YG1
1971 Yamaha 125 YAS-1
1968 Honda 125 SS
1970 Honda CD 175
1973 Honda CB500-4
Honda CX 500
    

6Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 8:00 pm

robmack

robmack
Life time member
Life time member
This should be repairable using techniques developed for repairing boat hulls. Look up the books that are published by Gougeon Brothers, Inc., the firm that makes West System Epoxy. Specifically the book entitled "002-550: Fiberglass Boat Repair & Maintenance", in Chapter 4 "Repairing Damaged Skins", it shows the techniques you're going to use on this repair.


__________________________________________________
Robert
1987 K75 @k75retro.blogspot.ca
http://k75retro.blogspot.ca/
    

7Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 8:09 pm

1990k75

1990k75
Silver member
Silver member
Point-Seven-five wrote:No way you'll make a decent repair with the part on the bike.  you will be working with some messy stuff and need to get at the back of the part.  It really isn't all that hard to remove that part.  about 10 screws and a couple 6mm bolts hold it on.  You can leave the main fairing and the radiator grille.

Yeah, that's what I was expecting...  Crying or Very sad

Well, at least the garage is heated...  Smile

Wifey Joanie will be thrilled that I'm in the garage & not at the bar (haven't been to a bar in the last 4 years LOL)

Guess I'll begin the fairing dismantling...


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

8Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 8:18 pm

1990k75

1990k75
Silver member
Silver member
Thanks Olaf & Robmack, I'll try to do a good job & post pics...

Now that I have the paint in hand thanks to Point-Seven-five, nothing to do but bite the bullet & get that fairing piece off Laughing


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

9Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 8:51 pm

92KK 84WW Olaf

avatar
Life time member
Life time member
Give a thought to a little black paint in the damaged area to avoid repainting the entire of the red panel. Black is good for hiding the road dirt too.


__________________________________________________
1992 K100LT 0193214 Bertha Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red 578 bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 689 58,645 now 106,950 miles Deceased.
1983 K100RS 0011157 Fricka 606 Alaska Blue 29,495 miles Damn K Pox Its a Bat outta Hell Now 58,200 miles. 
1996 K1100LT 0233004 Lohengrin Mystic Red 38,000 miles currently 48,061 miles.
1983 K100RS 0004449 Odette R100 colours 58,000 miles. Sprint fairing now 61,190 miles

Past:
1968 Yamaha 80 YG1
1971 Yamaha 125 YAS-1
1968 Honda 125 SS
1970 Honda CD 175
1973 Honda CB500-4
Honda CX 500
    

10Back to top Go down   fairing repair Empty Re: fairing repair Tue Dec 01, 2015 10:14 pm

indian036

indian036
Life time member
Life time member
92KK 84WW Olaf wrote:Lorne, that panel comes off very easy. So much nicer to be able to repair it inside in the comfort of home with a beer on the table.


Now to do the job you need fairing repair 905546712 :-c: Surprised-o:
Lots of good advice here, Lorne, but one thing to consider before you start - check the clearance behind where the repair will be done, especially at the leading edge, to ensure you don't build it up too thick to go back to where it should be on reassembly. 

Also, a modification to Olaf's advice:
 fairing repair 905546712 :-c: Surprised-o: fairing repair 905546712 fairing repair 905546712

Bill


__________________________________________________
1985 K100RT  VIN 0028991  My original Very Happy ROB the Red Old Bike   (Historic rego)
1985 K100RT  VIN 0029036  BOB the Blue Old Bike  (Historic rego)
1990 K100LT  VIN 0190452  Work in progress
1984 K100RT  VIN 0023022  Work needing lots of progress

1986 K100RT  VIN 0090542  Work needing lots and lots of progress
1993 K1100LT  VIN 0183046  Work in progress
1993 K75S  VIN 0213045  Tom the Triple (now on Historic rego too.)
    

11Back to top Go down   fairing repair Empty Re: fairing repair Wed Dec 02, 2015 1:41 am

1990k75

1990k75
Silver member
Silver member
Got it off Smile 

fairing repair Img_0411


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

12Back to top Go down   fairing repair Empty Re: fairing repair Wed Dec 02, 2015 1:45 am

1990k75

1990k75
Silver member
Silver member
And as you can see, took Indian's advice...  Beer drinker


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

13Back to top Go down   fairing repair Empty Re: fairing repair Wed Dec 02, 2015 3:17 am

charlie99

charlie99
VIP
VIP
some advice if I can add

the material of the fairing is quite prone to breakages in the same place ...even after repairs of sorts (blame flexing )

cut away a lot of the broken material  and try to file off some of the thickness on the affected area ....build up the repair in layers that over lay the old stuff  with a good amount of extra fiberglass matt that covers a greater area of the good part of the fairing as well .

else you will have cracks appearing around the repair

just what I have experienced

good luck


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
1987 k100rs ########   "Red"  - (red sports rs TWB style )
1989 K100rt #009637   "Black Betty"  (naked rt ala Nigel , now sporting an rs main fairing )
    

14Back to top Go down   fairing repair Empty Re: fairing repair Wed Dec 02, 2015 7:45 am

Dai

Dai
Life time member
Life time member
One addition to Robmack's link: where it shows scraping the crack out with a pointed tool, use a small rotary ball in the end of a Dremel or similar. It makes for a much more even slot for the filler and unlike the pointed tool, you don't have to put pressure on as the rotary ball will do all the cutting for you. Trust me (or maybe not!) - it does make life easier.


__________________________________________________
1983 K100 naked upgraded to K100LT spec after spending time as an RS and an RT
1987 K100RT
Others...
1978 Moto Guzzi 850-T3, 1979 Moto Guzzi 850-T3 California,1993 Moto Guzzi 1100ie California
2020 Royal Enfield Bullet 500
    

15Back to top Go down   fairing repair Empty Re: fairing repair Wed Dec 02, 2015 5:16 pm

1990k75

1990k75
Silver member
Silver member
Thanks guys for the added info, I will reinforce with some cloth...   Smile


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

16Back to top Go down   fairing repair Empty Re: fairing repair Wed Dec 02, 2015 5:22 pm

92KK 84WW Olaf

avatar
Life time member
Life time member
You need to watch too in case it overheats so after about a minute apply a teaspoon of PolarIce to the Dremel Operator to reduce the temperature.


__________________________________________________
1992 K100LT 0193214 Bertha Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red 578 bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 689 58,645 now 106,950 miles Deceased.
1983 K100RS 0011157 Fricka 606 Alaska Blue 29,495 miles Damn K Pox Its a Bat outta Hell Now 58,200 miles. 
1996 K1100LT 0233004 Lohengrin Mystic Red 38,000 miles currently 48,061 miles.
1983 K100RS 0004449 Odette R100 colours 58,000 miles. Sprint fairing now 61,190 miles

Past:
1968 Yamaha 80 YG1
1971 Yamaha 125 YAS-1
1968 Honda 125 SS
1970 Honda CD 175
1973 Honda CB500-4
Honda CX 500
    

17Back to top Go down   fairing repair Empty Re: fairing repair Thu Apr 21, 2016 11:52 pm

1990k75

1990k75
Silver member
Silver member
Totally copped out on this one. Winter was dragging on & I was spending a lot of time on the couch... Smile 

Took the panel to a local auto-body shop and threw money at them - re-installed the panel (thank you my digital camera) & now ready to ride, as soon as the last snow (yes, still snow here on my birthday April 20th) leaves the driveway   Laughing 

Thanks to everyone for the help

Cheers, Lorne & Joanie cheers


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

18Back to top Go down   fairing repair Empty Re: fairing repair Fri Apr 22, 2016 5:57 am

92KK 84WW Olaf

avatar
Life time member
Life time member
Excellent move and probably not a very expensive one.

Glad to see you are sorted, now for a photo?


__________________________________________________
1992 K100LT 0193214 Bertha Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red 578 bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 689 58,645 now 106,950 miles Deceased.
1983 K100RS 0011157 Fricka 606 Alaska Blue 29,495 miles Damn K Pox Its a Bat outta Hell Now 58,200 miles. 
1996 K1100LT 0233004 Lohengrin Mystic Red 38,000 miles currently 48,061 miles.
1983 K100RS 0004449 Odette R100 colours 58,000 miles. Sprint fairing now 61,190 miles

Past:
1968 Yamaha 80 YG1
1971 Yamaha 125 YAS-1
1968 Honda 125 SS
1970 Honda CD 175
1973 Honda CB500-4
Honda CX 500
    

19Back to top Go down   fairing repair Empty Re: fairing repair Mon Apr 25, 2016 3:19 pm

Point-Seven-five

Point-Seven-five
Life time member
Life time member
Just did a repair to the same part on my K75RT.  Bike got knocked over in the garage and the crash bar broke a 3" x 6" chunk out of the panel right in front of the vents. 

Here's how I repaired it:

1. Trimmed the fibres back to where it could get the chunk positioned properly in the panel.  Then I used cyanoacrilate glue to hold it securely in place.

2. With the chunk positioned, I carefully scratched up the back side of the panel with 80 grit.

3. After a second dose of C/A glue. I used my Dremel with a wire wheel to clean out the seam for the application of Bondo to make the seam level with the surface of the panel.  I carefully sanded the bondo for an even surface.

4. I used a lightweight fiberglass tape 2" wide that I got from a hobby shop.  R/C airplane guys use the tape for airplane repairs.  I cut 5-6 pieces to make three layers on the back side of the seam between chunk and panel.  I put the glass down with polyester resin and a 1" chip brush.  Paint the surface with the resin then lay the fitted pieces of glass in place so the fibers are running in different directions.  Press down and work the resin into the glass with the brush.

5. With the back side cured the panel is now strong enough to do the cosmetic work on the front.  Clean out the seam with the wire wheel in the dremel and fill with bondo.  Sand the Bondo, prime, and use a spot putty for minor defects.

6. Paint with base coat and take to a collision shop for the clear coat.

Total time to make the repair was about 4 hours over two days.  I didn't stop to take photos.  Can't post them here anyway.


__________________________________________________
Present: 1991 K100RS "Moby Brick Too"
 
Past:
1994 K75RT "Ilsa, She Wolf of the SS"
1988 K100RS SE "Special Ed"
1994 K75S "Cheetos"
1992 K100RS "Moby Brick" R.I.P.
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

20Back to top Go down   fairing repair Empty Re: fairing repair Mon Apr 25, 2016 10:11 pm

1990k75

1990k75
Silver member
Silver member
Good work Point-Seven-five, I went right to step 6 LOL.

Our bikes must be drinking in the garage, they keep falling down...  Laughing


__________________________________________________
Past bikes - Yamaha YL-1, Honda XL-125, 1967 BSA 650 Lightning

Current - 1990 K75RT (in drydock) & 1995 K75RT VIN # WB1056503S0372669
            - 2011 Suzuki V-Strom 650
            - 2011 Yamaha XT250

Who sez I'm too old to ride?
    

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