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Hard box repair

  • SWest
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10 Oct 2015 05:52 #694041 by SWest
Hard box repair was created by SWest
As suggested I'm starting a new thread on my boxes repairs. Last night I was able to use my heat gun to get the cracks to match. There is a gap where the plastic shrank on the bottom. That will be covered with fiber glass. I'm heading to Depot for supplies.












It will take another cleaning and light sanding to rough up so it will stick.
Steve

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10 Oct 2015 07:41 #694048 by missionkz
Replied by missionkz on topic Hard box repair
I was under the impression that fiberglass resin does not stick to PVC or ABS. HOWEVER Home Depot has all kinds of solvent plumbing glues that's perfect for that.
Also you can buy thin sheets of PVC and ABS from McMaster Carr or hobby shops.... form them with your heat gun to fit inside the cases for stiffness over those cracks and use that same solvent glue.
I have repaired a few PVC fairings in this manner, sanded the outside, used filler primer, sanded flat and smooth ... Repaint with rattle cans paints and they look great.

Bruce
1977 KZ1000A1
2016 Triumph T120 Bonneville
Far North East Metro Denver Colorado

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  • SWest
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10 Oct 2015 08:56 #694052 by SWest
Replied by SWest on topic Hard box repair
I don't see why it wouldn't. I'll try the lid on the other box. If it doesn't stick, then I'll have to do what you suggested.




Maybe use ABS glue with the fiber glass sheets?
Steve
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  • bluej58
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10 Oct 2015 09:15 #694055 by bluej58
Replied by bluej58 on topic Hard box repair
I really like this stuff, 4 years, somewhere around 35,000 miles and no trouble.



a hot glue gun does a good job of tacking pieces together





78 KZ1000 A2A
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  • z1kzonly
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10 Oct 2015 11:25 #694061 by z1kzonly
Replied by z1kzonly on topic Hard box repair
Basic fiberglass resin and fiberglass cloth! They sell kits at all the auto parts stores.
I have this 25 year old gallon of Dyna Hair, fiberglass, reinforced stuff!
Gonna finish my 3 piece fender one of these days!



Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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10 Oct 2015 13:06 #694069 by jackleberry
Replied by jackleberry on topic Hard box repair
I've used the ABS cement (nasty stuff!), some ABS sheet and a heat gun (to shape the sheets) to repair KZP cases. It works, but it certainly isn't the prettiest. If all you have is cracks and no missing bits, the ABS cement alone can repair it.

One of my cases was coated on the interior with fiberglass by a PO. It is way sturdier than the pure ABS cases and has never cracked, broken, or deformed. I guess that's anecdotal evidence that fiberglass will stick to ABS.

So I'd say fiberglass is the way to go for a good looking and durable repair. It sure is messy to work with though.

1997 KZ1000P (P16)
2001 KZ1000P (P20)

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  • SWest
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10 Oct 2015 13:25 #694071 by SWest
Replied by SWest on topic Hard box repair
After cleaning with thinner, I roughed up the areas with #100 and #80 paper.

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For those that haven't done this before, you fold the paper in half. Fold it back and forth a few times so it will tear easily at the seams.


Fold it again to make 1/4 sheets. They will now fit a sander, sanding block or fold it again to make hand sanding easier.
.

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Clean again.

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Brushed the thinner and it became like glue. Time to apply the first course of fiber glass.


It'll stick.

Attachment 009.jpg not found




Got in the corners.


Now to let it cure and apply another course.
Steve

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10 Oct 2015 16:43 #694084 by SWest
Replied by SWest on topic Hard box repair
Second course of glass and started on the hinges. Tomorrow I start on the outside. :whistle:
Steve



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10 Oct 2015 19:58 #694100 by Shabba
Replied by Shabba on topic Hard box repair
I was half joking when I suggested a write up but this is really interesting. I imagine the finished product will hold up well so you can use that insurance money elsewhere.

-Colin

-82 GPZ750
-15 Yamaha FZ-09
-00 Suzuki TL1000S
-13 Nissan Nismo Juke
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  • SWest
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11 Oct 2015 02:11 #694110 by SWest
Replied by SWest on topic Hard box repair
Thanks for the suggestion. That's what these threads are for. If someone needed advice on fixing a cracked or mangled hard box, they would never find it in the close call thread. It's holding together fine. When I made the initial call, I was told I could take it to a body shop, buy new ones, do it myself and spend the money any way I want. :whistle: I just won a Mustang LTD seat and am picking up other little things I needed. More to come. :woohoo:
Steve

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11 Oct 2015 06:56 #694132 by Barry2
Replied by Barry2 on topic Hard box repair
Now just keep a close eye on those Bozos out there so it doesn't happen again. By the way, nice work.

1976 KZ900
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  • SWest
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11 Oct 2015 17:30 - 11 Oct 2015 19:12 #694202 by SWest
Replied by SWest on topic Hard box repair
A little light sanding tomorrow and I can paint them. Even fixed some cracks on the other box.


I could spend more time on them and maybe I will later. Have some business to attend to 400 miles away. Need the boxes and a few other things done to do it.
Steve
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Last edit: 11 Oct 2015 19:12 by SWest.

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