Ideas for method to modify fairing piece needed

[robmack]

Hi,

I have a desire to customize my bike this winter, including eliminating the handholds on the tail cowl. To get an idea of what I want to accomplish, here are pictures of current state and future state:

<== Current state with handle and plastic insert

<== The future state "look" I'd like to achieve.

The tail cowl is formed fibreglass unit, and not a moulded plastic piece. The handle bolts onto the tail and is removable, as is the black plastic insert. This is what the part looks like with the handle removed.

What is puzzling me is what is the technique I should use to fill-in the void and contour the area once the handle is removed? I think I will have to build a form from some stiff wire netting or something to get the rough contour, and then fibreglass over that. Is there a better way to get this done that is both structurally sound and which looks good?

 

[Emefef]

Hi,

I have a desire to customize my bike this winter, including eliminating the handholds on the tail cowl. To get an idea of what I want to accomplish, here are pictures of current state and future state:

<== Current state with handle and plastic insert

<== The future state "look" I'd like to achieve.

The tail cowl is formed fibreglass unit, and not a moulded plastic piece. The handle bolts onto the tail and is removable, as is the black plastic insert. This is what the part looks like with the handle removed.

What is puzzling me is what is the technique I should use to fill-in the void and contour the area once the handle is removed? I think I will have to build a form from some stiff wire netting or something to get the rough contour, and then fibreglass over that. Is there a better way to get this done that is both structurally sound and which looks good?

Disclaimer: I'm not an expert, or even really really good at body work. I am however, experienced in "making do"!
I wouldn't worry as much about filling the void if you used material thick enough to cover it. It has that small ledge inside that you should be able to fasten a piece of something to first, then glass over it.
If you cut that inner piece off, it would be easier because you could work at it from both sides. Then you could lay fibreglass from the back side and only worry about filling it to smooth it on the front side.
With any luck, more experienced experts will chime in soon!

 

[Red_Liner740]

Expanding insulation foam.

Sand down the internal portion to be covered with rough sand paper. Use expanding foam as a filler. Cut excess off once dry and use it as the base to lay the fiberglass down.

 

[silverbullet132]

Expanding insulation foam.

Sand down the internal portion to be covered with rough sand paper. Use expanding foam as a filler. Cut excess off once dry and use it as the base to lay the fiberglass down.

++1

 

[robmack]

Thanks for the expanding foam idea. It is very sticky stuff so should adhere well to the keyed surface. I could even form a mould on the outside of the part using packing tape and inject foam through a hole drilled into the backside of the fibreglass. That way the foam would obtain higher density before setting, giving it greater crushing strength.

 

[TorontoBoy]

Cut a piece of plywood that will fit over the handhold void and sit on its ledge. You can use the handhold indentation turned upside down for the dimensions. Glue/screw this in. This will give you a very strong base. You might even need to add another piece of wood on top of this because the top of the void seems to be deeper than the rest (where the photo watermark is located). Then glass.

Same for the upper handhold support void.