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Old 07-13-2009, 12:29 PM   #1
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Question fender removal and plastic filler?

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Old 07-13-2009, 12:34 PM   #2
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R u needing something to mold etc for the box?

I have pieces of industrial strength foam, soft enough not to scratch glass but very durable. I kept them from windshields that were shipped to us.

its easily cuttable and still spongy(i can compress it w my hands about half an inch.) If you need it to fill the box so things dont slip out you can use it. I have it at work.
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Old 07-13-2009, 12:46 PM   #3
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Working on the bike inside! Awesome!
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Old 07-13-2009, 12:47 PM   #4
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Thanks. The items I to keep in the trunk shouldn't move too much but I may still take some of that foam.

I would like to fill in the gaps on the underside of the fender (where the tape is exposed) - see the part circled in pink in the photo below.

It should be something that can be smoothed at least a little bit - maybe something like Bondo but with some actual strength? Maybe I will use it in the interior side instead of the tape too.


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Old 07-13-2009, 12:55 PM   #5
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epoxy?
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Old 07-13-2009, 01:08 PM   #6
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Quote:
Originally Posted by burnboy View Post
epoxy?
That is what I am asking about -

From my reading online last night about people with similar projects - some people say don't use epoxy (something about adhesion) or that I needs some special "plastic fixer" or that I should melt plastic in place if I want it to have any strength.

So that is what I am asking. I need to recreate the inverse of the box I removed. When I get done it should be sealed and reasonably smooth under the fender so water and dirt don't get inside the trunk.
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Old 07-13-2009, 01:09 PM   #7
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cali has a plastic welder.
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Old 07-13-2009, 02:58 PM   #8
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Oh chit my bad. Ya plastic weld it, then begin w a corse sand paper and end w a fine sand paper to clean it up. It wont look perfectly molded but it will fill it.

Lemme know if you wanna pick it up at work or if you want me to bring it home and meet you somewhere.
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Old 07-14-2009, 11:43 AM   #9
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update:

Big thanks to Cali for the plastic welder. I need more practice and more patience but it got the job done. I broke a weld when I tightened everything up so I need to fix that tonight.

after the sloppy plastic welding and some sanding
fender removal and plastic filler?

fender removal and plastic filler?

more sanding and a touch of flat black spray paint:
fender removal and plastic filler?

fender removal and plastic filler?

Final mockup:
mockup


I still need to get some lights for the plate, repair the weld I broke and then reassemble everything.

So far total cost is $0 - and lots of labor (but very little actual sweat).
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Old 07-14-2009, 04:50 PM   #10
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Lookin good bud!

U can get hyperwhite leds and drill holes just for the led to poke through(has a shoulder to prevent it going all the way through.) They dont last too long, about 6months a piece and the angle is narrow not wide. I always run two of them for redundancy. They are usually available at Discount AutoParts.

Or check w Patrick on the LED license plate bolts w leds
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Old 07-20-2009, 09:23 AM   #11
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final pics

side view
fender removal and plastic filler?

rear view
fender removal and plastic filler?
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Old 07-20-2009, 10:30 AM   #12
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glad i thought of the plastic welder,lol.
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Old 06-01-2010, 07:33 AM   #13
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Nice. Thats will be my next mod!
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