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Motorcycle Fairing Repair with PlastiFix

VideoClick here to see the video of this repair

Step 1

Motorcycle plastics are often discarded because of small cracks in the fairing. This will show how to use PlastiFix to repair a crack in a motorcycle fairing.

The crack in this fairing is typical of what you find in a broken motorcycle fairing.

Clean the damaged area. Some contaminants, like tar or grease, will not come off with soap and water. Super Clean is a mild solvent based cleaner that will remove these contaminants. Use a clean cloth or paper towel and wipe in one direction to avoid recontaminating the surface.

Step 1
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Step 2

Align the crack. You may need to hold the alignment in place with aluminum body tape. On this crack, tape is not necessary.

Use a rotary tool with a teardrop shaped cutting bit and grind about halfway through the plastic along the crack line.

Be sure to round off any sharp edges.

Step 2
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Step 3

Use a DA sander with 180 grit sandpaper to remove the paint surrounding the damage and to radius into the damage.

Motorcycle Fairing Repair
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Step 4

Squeeze 2 or 3 drops of liquid onto the powder then use the tip of the needle to stab the ball of liquid and powder.

Plastex Repair Kit
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Step 5

The hole of the needle is on the side of the needle. Not at the tip. When you transfer the ball of liquid and powder to the crack, give the bottle another squeeze. The liquid will run down the side of the needle and wash off the ball. Continue using this method until the crack is filled with plastifix.

Allow plastifix to cure fully before working on the opposite side.

Fairing Repair
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Step 6

Use a rotary tool with a teardrop shaped cutting bit and grind about halfway through the plastic along the crack line.

Be sure to round off any sharp edges.

Street Bike Fairing Repair
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Step 7

Just as you did on the opposite side, fill the v-groove with plastifix and allow the PlastiFix to cure fully.

Apply PlastiFix
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Step 8

Use a rotary tool with a teardrop shaped cutting bit and remove any excess plastifix until level of the plastifix is slightly below the level of the surrounding plastic.

Remove Excess PlastiFix
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Step 9

Mix and apply Flex Filler to the repair area. Allow the filler to cure fully before sanding.

Apply filler
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Step 10

Sand the filler to the correct contour and finish sanding with 320 grit sandpaper.

Sand filler
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Step 11

Sand any area where primer will be applied with 320 grit sandpaper.

Tight spots may need to be sanded by hand.

Sand Fairing
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Step 12

Apply a high build flexible primer surfacer and allow time for it to dry.

Apply primer
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Step 13

With 320 grit sandpaper, sand the primer until the entire part has a smooth finish that is ready for a top coat.

Block Sand Primer
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Step 14

Apply the top coat according to the paint manufacturer’s recommendations. Here, we are applying a basecoat and clearcoat.

Paint
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Products Used For This Repair

1000-A
Super Clean (aerosol)
$ 14.95
2501
PlastiFix Kit (White)
$ 35.95
6121-T
Tear Drop Cutter Bit
$ 8.95
2000-T
Flex Filler, Tube Kit
$ 25.95