PLASTIC WELDING HINTS TIPS AND ADVICE WANTED

[GERONAMO308]

Hi all, does anyone know what type of plastic is used for making ATV fairings.

In particular Suzuki Quadrunner 1992, if i cannot get a plastic for it in Red for the rear i will attempt repair.

I have a King Chrome plastic welding kit, however you need to know what type of plastic you are welding.

Any advice would be greatly appreciated. 

[joninak]

...Following.

I have a few holes I'd like to fill in on some camo fenders.

[jen]

Wow great issue.  I was looking at the Dewalt plasitc welder.  A lot depends on the type of plastic.  The fairing on my Kawsaki is ABS plasitc.  I have been using  my soldder gun to repair internal mounting pieces.

I use pieces of scrap ABS plastic as a "filler rod".   That helped.  

Would love to know if the Dewalt is a good option.

[Gwbarm]

I have the Harbour Freight one it works well, i have never seen a Dewalt one.

[jen]

They had one a year ago.  However, i cannot find it listed now.    I have not worked on Outsside/ finished repairs.  I would probably use a Vinyl decal or sheet to cover.

I have tried reinforcing ABS broken mounting tabs with Epoxy glue and metal.  That did not hold well.  Welding appears to be best.

I'll look at Harbor Freight  ...And Wal Mart  ha-ha  I have Wal Mart stock. 

[Gwbarm]

Mounting tabs are tough because you dont really have enough platic to repair with, the tool comes with some fine screen that you can cut and melt into the plastic to give it some support. I have had better luck repairing those with fiberglass with the cloth and the resin, very messy and lots of fumes.

[jen]

OMG..I never thought of that...I have done a lot of Fiberglass repair.  I have an Epoxy (slick racing) paddleboard that i have repaired . Plus i rebuilt the nose on my cousins paddle board..  

I don't paddle board race but gives me a chance to wear my Bikini ...LOL  The Banana River Mangrove hammocks  are one of my favorite paddle boarding places.

The West Marine epoxy is pricey but wow is it full proof to use.  Moreover, they love to talk to neophytes like me.

[tartanpion]

Hello,

with the Suzuki motocycle fairings, ABS, i have done a repair after a crash on track.

1. I crush lego toys (or parts of unpaint ABS) in a glass jar and melt it with acethone. I let it work one night in the sealed jar.

2. I make a chamfer on the broken part and clean the welding zone with acethone.

3. I pick up the paste in the jar, and spread it on the broken part.

4. It will be fixed 24h later.

5. The process may twist the original part because the ABS is melting. And i have soak the knive blade in acethone before spreading the paste because of the ability of the paste to adhère to the knife.

[jen]

That sounds doable...I will send you a picture when I get back to Florida.

I have  mounting tabs on My 1992 Concours fairing i need to fix as* I am selling it ( Its just too heavy for me butt kick as* ride..) need a lighter bike.

[tartanpion]

Ok, you can position the broken part with a soldering iron before using thé lego paste.

It is possible to create a color part similar to the fairings by melting différents colors of lego. I have infortunetly create a pretty orange KTM...

It is important to spread the paste on a horizontal surface.

You can add ribs to make thé part stronger.

Perhaps, adding galvanised wire mesh inside the paste, can make thé same effects as reinforced concrete. But i have not done that.

[John Chappell]

One of the most common plastics used on ATVs is HDPE (High-Density Polyethylene).  You can get HDPE filler rods, or you can cut up something like a 5-gallon bucket or lid from Home Depot, Lowes, or Harbor Freight because they are usually HDPE as well.  Of course the best match for material and color you can get is to "borrow" some plastic from somewhere else on the ATV that's not visible or necessary.

[tartanpion]

This is some outside and inside picture of the wounded parts. You can see the welding paste in orange. The parts have not been painted yet, but i have done 25 000 km with the vibrating tl1000r vtwin sportbike to validite the process.

[jen]

have you used fiberglass cloth or fiberglass mat as reinforcing?  

[tartanpion]

No, just melted crushed lego (m'y toy when i was child🥺) and acethone,  i make a space between the two parts, and hole at the end of the crack. The mean problem is bubble in the welding, you can see it on the last picture.

I think it is possible to weld something printed on abs 3D printer to other parts with this method.

[jen]

 pictures...that always helps a Post.

 

J Chappell  Posted that ATV's are HDPE...did not know THAT.  My Kaw motorcycle is ABS

[Mech]

There are simple tests to identify what sort of plastic you are dealing with. I have it in a book but it should be findable online somewhere..  Google "identifying plastic types" perhaps.

[jen]

Hmmmm....I'll look

[Mech]

Plenty of information there I see. Once you know the plastic type, google "welding" that type of plastic. The technique varies with plastic type..

[jen]

I need to weld the plastic fairing mounts. But also I need to paint or refinish the outside surface.  In Florida the road sand "sand blasts the lower portions of my fairing.

But first thing is get it monted,

The front finder is cracked about half way across right at tbe fork mounting cross brace.  I was thinking about reinforced epoxy resin on the underside .

But Ill check but I am almost positive its ABS.

[Mech]

Gw sounds like the man for bringing plastics back to life..

[jen]

The fender crack is held by the brace.  However, I need to be sure what type of plastic is mine .  Then send him some pictures so he can see my crack.  The crack is tight and I still ride with it.  

[shorty]

If there's enough surface area on the underside of the damage, I like to scratch it up and use fiberglass cloth and epoxy resin. Don't use polyester resin.. welding is good too if it's a crack that still closes up tight 

[jen]

Yes it closes tight...only about one inch, clean crack.  It's tight unless you pull it open.

[shorty]

Then I believe heat welding would fix that. Soldering iron with some ABS plastic scrap should work 

[jen]

I've done the soldering iron ...i was going to buy the plastic welder for fender ...Not enough hours in the day  or night LOL

[jen]

i did he soldering iron on fairing . have not tried the fender crack