Epoxy Cracked Side Cover

[BULLY]

Paint and pin striping are perfect on my 81GS1000G. However, one has a stress crack from previous owner pulling on it wrong. Can I sand and gouge some material on back side and apply epoxy for a repair or will I need to replace it?

Any other info would be great!

BULLY

http://i596.photobucket.com/albums/tt47/alsohim/DSC_3394.jpg?t=1269389097

[Guest]

Use fiberglass.

[posplayr]

Here are some pics in Photobucket. The key is to feather out the crack so there are no "butt joints"

http://s449.photobucket.com/albums/qq215/posplayr/GSR/GS750_Tank/GS750_Prep/

[Nessism]

When repairing a cracked side cover I make sure the crack is open just enough to get epoxy into the crack, and then I rough up the inside of the cover in the crack area and laminated on a good sized patch of fiberglass cloth with epoxy.

[bonanzadave]

This is a 20 gallon fiberglass wing tip fuel tank we make at work. Its two 1/2 shells bonded together with Loctite 9460 epoxy. Strong chit !

[crazypaint]

its called plio-grip (2-part epoxy) good **** lol use a grinder and feather the edges out on both sides with 36 grit. blow clean apply the epoxy sand smooth with 80 then 180 sandpaper then apply a layer of iceing (type of bondo) sand with 180 prime that with 3 good coats sand that with 320 then use a sealer then color then clear

[BULLY]

Thanks guys good tips! My hope is to make this repair without having to repaint the excellent paint on the cover.

[tkent02]

Here's a similar thread from a couple days ago, good info.

http://www.thegsresources.com/_forum/showthread.php?t=158810

[posplayr]

Thanks guys good tips! My hope is to make this repair without having to repaint the excellent paint on the cover.

To save the original paint, sand down the back around the crack as thin as you dare; fill in with a 15 minute epoxy called "Plastic Weld"

http://www.permatex.com/products/automotive/auto_adhesives_sealants/epoxies.htm

You can either fiberglass over the back of that or use some "Cat Hair" Bondo (long hair stands); that should reduce the
chance of further stress cracks coming to the surface