Topic: How to repair shattered side cover?

[B.O.X.N.I.F.E.]

I've seen some great threads on repairing cracked side covers, but mine had been shattered at one point and is missing an entire little piece.

Are there any proven methods to build up this gap? Not sure what products are out there.

[OldSchool_IsCool]

Tagging up because enquiring minds want to know!!

[333]

Time to learn fiberglasing.

[Gordon]

Not to discourage you from learning how to repair it yourself, but since you're already going to have to repaint it why not buy a new or good used one? 

[Nikkisixx]

A fiberglass repair kit is less than $20 at the local hardware.  A new cover or good used one is not that inexpensive.  I glass the entire back side of covers, and they are much stronger after doing so.

[Gordon]

Is the missing piece where the mounting tab was, or is that on the other corner?

[FrankenFrankenstuff]

They were made out of crappy old ABS material. Fiberglass sticks well if you clean, sandblast, wax and grease remover, then scuff. I actually have fixed a couple simple cracks using Methalene Chloride. It chemically melts the crack sealed. Dont try to use Bondo, or some cheapo' plastic epoxy....your just covering up the cracks.

[BeSeeingYou]

PVC/ABS cement used for plumbing fitting will work to glue cracks together.  It worked well for me when I repaired a crack and then I beefed up the backside with epoxy resin and fiberglass cloth.  Looks like your panel could benefit from that.  Make sure you get epoxy and not polyester (fiberglass) resin which may be what comes in small auto body type repair kits.  Polyester is fine for some things but epoxy will bond better with PVC/ABS plastic.  Sand the backside and lay on some cloth and use a cheap foam brush to apply the epoxy.  It may be easier to give the backside a quick coat first as that will help hold the cloth in place and help out the wetting process.  You can also get many additive powders for epoxy to alter it's properties and handling characteristics. Add low density filler to make a putty that will sand easier and high density filler to make structural repairs like tabs.  I work with boats so I always have good quality epoxy laying about.  West System or Systems Three is what I use.  At one time these companies would send out small starter/test kits cheap don't know if they still do.  I could probably get a small kit together for you if you have a hard time finding what you need.

crack glued with PVC/ABS cement.


Beefed up the tabs with high density filler.

[Stev-o]

Box - is that a left or right - I may have an extra.

Another member just sold a blue one for $25.

[FrankenFrankenstuff]

[Stev-o]

Box - is that a left or right - I may have an extra.

Another member just sold a blue one for $25.

http://forums.sohc4.net/index.php?topic=73580.0

[BeSeeingYou]

Yeah it's probably easier to get some repro's and with the cost of quality epoxy, fillers, and cloth just as cheap.  I take it that is what your post is saying.  

[B.O.X.N.I.F.E.]

The F series covers aren't reproduced yet.

There were some in the for sale section I just missed. The set and the single ones are all sold, I've PM'd them.

[david 750f]

I think you can get repo 550F side covers at LPM.
http://lpmreplicaparts.com/honda/CB550F/sidep.html

[Stev-o]

I think you can get repo 550F side covers at LPM.
http://lpmreplicaparts.com/honda/CB550F/sidep.html

Not a bad price, $102 for a pair shipped to US.

[B.O.X.N.I.F.E.]

I think you can get repo 550F side covers at LPM.
http://lpmreplicaparts.com/honda/CB550F/sidep.html

Wow, that's where I'm going for side covers from now on.

I can't find Methalene Chloride anywhere local, will MEK work for melting cracks back together? I looked for Rock Miracle, a methalene chloride product, but can't find that either.

[octagon]

b weld works well - you can lay a wide layer of it on either side of a crack on the back side of the cover, and then pat fiberglass cloth into it - the jb weld will slowly soak into the cloth - makes a light very strong repair.

[B.O.X.N.I.F.E.]

I ended up using this method, sort of. Sourced a pile of cracked covers from a forum member, sanded them and used the clear Oatey cement. I had to use crappy insulation grade fiberglass, but will get the good stuff next time.

Acetone and that cement pretty much melt the ABS back together, this is the best way to do it in my opinion. Will post pics when done.

PVC/ABS cement used for plumbing fitting will work to glue cracks together.  It worked well for me when I repaired a crack and then I beefed up the backside with epoxy resin and fiberglass cloth.  Looks like your panel could benefit from that.  Make sure you get epoxy and not polyester (fiberglass) resin which may be what comes in small auto body type repair kits.  Polyester is fine for some things but epoxy will bond better with PVC/ABS plastic.  Sand the backside and lay on some cloth and use a cheap foam brush to apply the epoxy.  It may be easier to give the backside a quick coat first as that will help hold the cloth in place and help out the wetting process.  You can also get many additive powders for epoxy to alter it's properties and handling characteristics. Add low density filler to make a putty that will sand easier and high density filler to make structural repairs like tabs.  I work with boats so I always have good quality epoxy laying about.  West System or Systems Three is what I use.  At one time these companies would send out small starter/test kits cheap don't know if they still do.  I could probably get a small kit together for you if you have a hard time finding what you need.

crack glued with PVC/ABS cement.


Beefed up the tabs with high density filler.