Topic: Side cover reinforcement

[emlupi]

Hello all,
I am looking to reinforce a set of original 750K2 side covers. I am considering using fiberglass and epoxy to add some strength to them. Any ideas or tips are appreciated. Thanks

[Stev-o]

Why not just buy new?  The posts will most likey break off at some point and then you are SOL.

Forum member Frankie makes them...

http://forums.sohc4.net/index.php/topic,74022.0.html

[flybox1]

Why not just buy new?  The posts will most likey break off at some point and then you are SOL.

Forum member Frankie makes them...

http://forums.sohc4.net/index.php/topic,74022.0.html

+1
I've had mine for 3 years now.  Still rock solid.  Perfect fit.

[emlupi]

I hear you, but it's my intention to keep this bike "as is" (at least for as long as I can). The tank has the patina of its years on it and I would like to keep the side covers the same. So, that said, any advice or tips on strengthening the originals would be appreciated.

[flybox1]

Replace those rubber grommets that hold the posts.  Old hard ones can stress the posts when removing.

[grcamna2]

I hope you don't care if the back-side of them look 'fixed' because i will tell you what I used.I purchased some fiberglass 'cloth' and then went to the local auto parts store and bought a tube of that 2-part epoxy/syringe.I then used a Dremel to make the rear surface i would be repairing nice and rough and washed it in the sink w/ dishwashing liquid,rinsed it and let it dry completely.I cut a piece of that fiberglass cloth to fit,then I starting squeezing out some epoxy(you got to do this quick)onto the back of the sidecover and used a small plastic squeegee to smooth it;then I layed the piece of fiberglass cloth into the epoxy that i just put onto the sidecover and then squeezed-out some more epoxy onto the top side of the cloth and used the squeegee to press as much of the epoxy mix into the cloth that I could until the cloth was sandwiched between the 2 layers of epoxy and it's held-up great and the crack has never opened up at all even though you can tell it was cracked from the outside.
I also get some fiberglass 'dust' from a body shop to mix together w/ the epoxy to form a strong 'paste' to put on the back areas of the sidecover posts to strengthen them.I say again though that you must work very fast as that epoxy will dry quickly.

[ekpent]

 Putting some grease on the rubber grommets and side cover posts make them come off and on easier. Putting your finger inside and pressing on the post and pulling off gently and correctly are important for these fragile covers also. Reinforce any cracks you may have now with some JB Weld on the backside after sanding the area a little to get good adhesion.

[grcamna2]

Putting some grease on the rubber grommets and side cover posts make them come off and on easier. Putting your finger inside and pressing on the post and pulling off gently and correctly are important for these fragile covers also. Reinforce any cracks you may have now with some JB Weld on the backside after sanding the area a little to get good adhesion.

I've used JBWeld also w/ good success.

[ekpent]

Putting some grease on the rubber grommets and side cover posts make them come off and on easier. Putting your finger inside and pressing on the post and pulling off gently and correctly are important for these fragile covers also. Reinforce any cracks you may have now with some JB Weld on the backside after sanding the area a little to get good adhesion.

I've used JBWeld also w/ good success.

Theoretically you could prep up the area and probably put some JB Weld around the post areas to strengthen them up as a precautionary measure if one were so inclined.

[RAFster122s]

If you want to get crazy buy some Kevlar Tow and epoxy it to the back side criss-crossing across the cover and on the posts lengthwise and a couple wraps around.  You can use just a bit of CA glue to tack them in place.  It is too brittle to use as the primary glue.  But some 30 minute epoxy to give yourself more working time.  A splash of denatured alcohol can thin the epoxy to allow it to flow, you want the tow surrounded by epoxy in a very thin layer.  More epoxy is not stronger, it is just more weight and no added strength per se.  Don't overdo the denatured alcohol as it weakens the bond and when too much is used it is severely affected.  10% is generally enough to thin and slow the cure.  Use the epoxy in a warm room, 70F, or the cold can retard or prevent the proper setting of most epoxies.

New grommets and bit of silicone grease is good recommendations.
Old grommets can actually make it easier to lose a cover as they do not seat properly. Itis well worth the $10 to replace.

[Stev-o]

Putting some grease on the rubber grommets and side cover posts make them come off and on easier. Putting your finger inside and pressing on the post and pulling off gently and correctly are important for these fragile covers also. Reinforce any cracks you may have now with some JB Weld on the backside after sanding the area a little to get good adhesion.

I've used JBWeld also w/ good success.

I have too but it's really only a temp fix

[emlupi]

Thanks for the replies. I have already bought all new OEM grommets and I have heard about the method of greasing the posts for easier removal. I believe I will do the fiberglass and epoxy application to help give the covers a little extra strength.

[ekpent]

Thanks for the replies. I have already bought all new OEM grommets and I have heard about the method of greasing the posts for easier removal. I believe I will do the fiberglass and epoxy application to help give the covers a little extra strength.

One pointer after doing finishes etc. over the years would be to first test a small area with whatever solvent based product you choose to make sure there is not a severe adverse reaction to the plastic that could ruin your project.

[grcamna2]

Thanks for the replies. I have already bought all new OEM grommets and I have heard about the method of greasing the posts for easier removal. I believe I will do the fiberglass and epoxy application to help give the covers a little extra strength.

One pointer after doing finishes etc. over the years would be to first test a small area with whatever solvent based product you choose to make sure there is not a severe adverse reaction to the plastic that could ruin your project.

Yes, The 2-part epoxy I purchased from Advance said it was safe for ABS plastic.

[TheArchitect]

I have used this on old fiberglass, really "rejuvenated" it. Seems to be absorbed by it.

https://www.flood.com/products/paint-additives/penetrol-oil-based-paint-additive

I was planning to use this on the insides of my side covers as well to see if it would help with the brittleness.

No idea how it will work with the plastic...

[Don R]

 I bought a bike that had been repaired by painting the cracks with acetone to weld the edges and then reinforced with fiberglass. It seemed very strong and lasted as long as I owned it.