![Crying or Very sad :cry:](./images/smilies/icon_cry.gif)
Offending corner with a pretty comprehensive (and very heavy) fibreglass repair.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/22092010178.jpg)
It's rougher than it looks in the photo, plus it constantly cracks at the junctions with the plastic, and the overlap onto the plastic makes a poor fit to lower section.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/22092010170.jpg)
Template shape is marked onto a piece of cls timber, and cut. Note - taken from good original side !
![Image](http://i56.photobucket.com/albums/g191/tambo_01/22092010172.jpg)
Shaped timber former next to portion to be repaired. See how out of shape the fibreglass is !!
![Image](http://i56.photobucket.com/albums/g191/tambo_01/22092010173.jpg)
Required shape is cut from new sheet of ABS
![Image](http://i56.photobucket.com/albums/g191/tambo_01/21092010166.jpg)
Dressed ABS is placed on curved timber former, and heated with hot air gun until it 'falls' into profile.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/22092010174.jpg)
Similar smaller section if cut and shaped on former to give the inner lip, and overlap to fix to remaining fairing.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/IMG0002A.jpg)
Inner section is glued to outer section using plumbing solvent, and plastic welded through holes when space allows.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/IMG0011A.jpg)
Ready for insertion !!
![Image](http://i56.photobucket.com/albums/g191/tambo_01/IMG0008A.jpg)
Offending portion of fairing removed, and overlap portions skimmed so that outer finish lines up well.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/IMG0005A.jpg)
Patch glued in place, and plastic welded.
![Image](http://i56.photobucket.com/albums/g191/tambo_01/IMG0013A.jpg)
I've used the same process to replace burst holes on the lower portion of the fairing as well
![Cool 8)](./images/smilies/icon_cool.gif)
Time consuming, but worth it
![Mr. Green :mrgreen:](./images/smilies/icon_mrgreen.gif)
Some more photos of repairs
![Image](http://i56.photobucket.com/albums/g191/tambo_01/09102010024.jpg)
![Image](http://i56.photobucket.com/albums/g191/tambo_01/09102010022.jpg)
![Image](http://i56.photobucket.com/albums/g191/tambo_01/09102010021.jpg)
Just the paint to do now. Was going to try Bike Colours aerosols after speaking to them as Stafford - will let you know how it goes.
This is a good man to use for decals sales@signs-services.co.uk
Fast, well priced, and he'll do any combination you like. I've changed the yellow 's' in kr1-s to red
![Cool 8)](./images/smilies/icon_cool.gif)