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Re: SPAL's 1993 Fireblade cleanup [message #219006 is a reply to message #219001] Tue, 27 July 2010 01:20 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi All,

Carried on with the caliper cleaning/overhaul and finished the second front caliper.

All pistons freed off - which is good.

Refitted headlight bracket to front top fairing, which allows me to mount infil panels and check how much I've got to build up to repair hole.

index.php/fa/16467/0/

index.php/fa/16468/0/

THe way it was previously repaired was a right dogs dinner but i'm reasonably happy that I can fabricate the section using plastex.

SPal

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Re: SPAL's 1993 Fireblade cleanup [message #219024 is a reply to message #215015] Tue, 27 July 2010 17:15 Go to previous messageGo to next message
lloydiecbr is currently offline lloydiecbr  UNITED KINGDOM
Messages: 145
Registered: December 2008
Location: coventry
(3) BSB Racer
http://www.wemoto.com/bikes/Honda/CBR_900_RRR_RRS_Fireblade/ 94-95/picture/Rebuild_Kit_Full_Seals_Caliper_-_Front/
try wee moto
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Re: SPAL's 1993 Fireblade cleanup [message #219035 is a reply to message #219024] Tue, 27 July 2010 20:59 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi Lloydie,

Good site,

Thanks

SPal
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Re: SPAL's 1993 Fireblade cleanup [message #219038 is a reply to message #219035] Tue, 27 July 2010 21:08 Go to previous messageGo to next message
drew70 is currently offline drew70  UNITED KINGDOM
Messages: 1508
Registered: January 2007
Location: Edinburgh
(8) 250 GP Racer
Hi bud you got your work cut out for ya with them fairings, good luck. Lookin forward to the results Thumbs Up
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Re: SPAL's 1993 Fireblade cleanup [message #219041 is a reply to message #219038] Tue, 27 July 2010 21:22 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi Drew,

Don't I know it Laugh

I figured that the fairing as it stands is scrap, I've already bought the plastex kit and done the repairs I needed it for, so might as well have a go.

If it all fails I'm in no worse position than I was other than having spent - was going to say wasted, but its all practise, so it won't have been wasted, a bit of time.

If it comes off, result. Thumbs Up

If not - oh well.

SPal
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Re: SPAL's 1993 Fireblade cleanup [message #219043 is a reply to message #219041] Tue, 27 July 2010 22:18 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi All,

Started the "Top Fairing repair".

As you can see from the previous pics, all i initially wanted to do was to get somethig in the hole.

I used tape to cover the hole, poured the "plastex" dust into the hole and squeezed the fixer onto it. I wasn't sure how long to leave it and after 5 mins took tape off to find a really thin layer of plastic.

index.php/fa/16474/0/

I re applied the dust and built it up in layers, smoothing each layer to as near as the contour i wanted as posible.

After about 3 or 4 applications. some on outside a some inside I'm left with this.

Didn't want to go too mad tonight as I figured it may be best to let fully dry overnight and continue building up tommorrow.

index.php/fa/16475/0/

Must say I am blown away by how good this stuff is. I know I've been optomisic thinking I could get both sections done with the same bottle, but as only £10.00 per kit compared with cost of replacing its real value for money.

SPal

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Re: SPAL's 1993 Fireblade cleanup [message #219053 is a reply to message #219043] Wed, 28 July 2010 00:36 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi,

Carried on with the fairing upper repair:

This is how the bullet hole bit has finished up for time being, I want to get totally dry B4 taking a template of the curve, from the good side and checking out.

I purposly built up more than I think it needs to be so I can mark new plastic and trim down to correct size.

index.php/fa/16478/0/

Moved onto side of panel, to try and get some bits bonded in and get some strength back into the panel. As the most trickyest bit is going to be the air scoop, I started trying to build up around the indicator stalk hole.

Luckily I had spare indicator grommets so used on, inserted into the hole to build up around.

index.php/fa/16479/0/

Thats how I'm leaving until fuly dry, when I will try and remove grommet and complete hole.

Been on ebay and ordered bigger kit of "plastex".

SPal

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Re: SPAL's 1993 Fireblade cleanup [message #219070 is a reply to message #215015] Wed, 28 July 2010 08:17 Go to previous messageGo to next message
Swiss T  UNITED KINGDOM
Messages: 5166
Registered: February 2004
Location: Sunny Stockport
(14) Eddie Lawson
Everyone loves a tryer Thumbs Up

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Re: SPAL's 1993 Fireblade cleanup [message #219080 is a reply to message #219070] Wed, 28 July 2010 16:58 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi Swiss,

Ha Laugh

Left plastex to go off thouroughly overnight and this afternoon carefully removed rubber indicator grommet.

Plastex had fully filled complete grommet so that it works like it did originally. Grin

As I've not got a lot of plastex dust left I've just done 1 strip across top of hole to roughly the point the air scoop starts to go in.

Still thinking of best way to fabricate the scoop, as I need a mirror image of the one on the other side, I'm thinking of blanking off the hole, filling with plaster of paris (or equivalent) then when set and I can remove from hole, covering plaster cast with fibreglass and when this is set using as a mould to cast a plastex replacement.

Thinking I will have to coat fibreglass mould with something like tape etc as plastex seams to bond to pretty much everything and I want to be able to get the finished scoop out of the mould when cast.

If anyones ever done anything like this before, please share....

Thanks

SPal

Oh nearly forgot, picked up head from bike shop as well, last stud extracted and helicoil fitted.

Fitted engine casings together as complete lump, now waiting for saturday when powder coat guy drops off first lot of bits and takes engine away to be cleaned and stove enamelled.
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Re: SPAL's 1993 Fireblade cleanup [message #219085 is a reply to message #219080] Wed, 28 July 2010 18:28 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi All,

Cause I know how much you all love watching me f**king about with plastex I thought I'd update you in case you were having difficulty containing your excitement as to how the erpair was progressing Laugh

AS mentioned in previous post, I'm really happy with way indicator hole has gone.

index.php/fa/16480/0/

THe good thing about this stuff is that you don't have to slogde great lumps of filler on the inside of the panels.

index.php/fa/16481/0/

Con't

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Re: SPAL's 1993 Fireblade cleanup [message #219086 is a reply to message #219085] Wed, 28 July 2010 18:33 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Con't

As I said earlier, the scope is the hardest bit to do and i've taken a pattern off the good side.

I'll be using this to align the new plastex scoop into the right place.

Masked off good scoop so that the plaster of paris dosn't bond to the fairing, I know its unlikely but knowing my luck I'll screw up the "good side" as well.

index.php/fa/16482/0/

AS you can see I've covered in the hole as obviously the plaster would run out and I need a full mould, which I will cut down when grafting back to the "bad side".

Be off to get some plaster of paris in morning.

SPal

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Re: SPAL's 1993 Fireblade cleanup [message #219094 is a reply to message #219086] Wed, 28 July 2010 19:21 Go to previous messageGo to next message
SP2 Riley is currently offline SP2 Riley  UNITED KINGDOM
Messages: 3956
Registered: January 2008
Location: peterborough
(11) MotoGP Podium Finisher
fooking lime light merchant GET ON WITH IT Laugh

its going well and it looks like you may get a good result. Thumbs Up


ps ive a good cure for tennis elbow when your ready after all that rubbing down Wink
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Re: SPAL's 1993 Fireblade cleanup [message #219098 is a reply to message #219094] Wed, 28 July 2010 19:26 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Oh, soory too much information 4 u. Grin

I thought as this is "cutting edge" stuff u wouldn't want to miss anything, but how wrong could I be! Grin

Its ok, I've got a small child to do the rubbing down, they have smaller hands, so can get into all the small orifices.

And there are cheep.

Opps - Above paragraph probably probably contravenes some european law or something. (just pretend I'm in China, it will be ok)

SPal Twisted Evil



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Re: SPAL's 1993 Fireblade cleanup [message #219141 is a reply to message #219098] Wed, 28 July 2010 22:32 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi All

unconerned by Riley's comments, I took a measurement of the scoop on the good side, Plastex looks really soft, but drys like concrete si i dont really want to build up any more than i need to.

The template:

index.php/fa/16484/0/

Matched up template with bad side and put on tape so that I could build upto the edge of the template.

Have used up all the plastex I havem so I know you will all be gutted, but you'll have to wait untill more plastex arrives.

THe Hole ( its geting smaller) baby.

index.php/fa/16485/0/

Preview : Tune in tommorrow 2 se if the plaster of paris mould thang works (bet u cant wait can you)/

SPal Cool

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Re: SPAL's 1993 Fireblade cleanup [message #219142 is a reply to message #219141] Wed, 28 July 2010 22:35 Go to previous messageGo to next message
drew70 is currently offline drew70  UNITED KINGDOM
Messages: 1508
Registered: January 2007
Location: Edinburgh
(8) 250 GP Racer
On the edge of ma seat Laugh
But seriously looking forward to seeing how it turns out Thumbs Up
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Re: SPAL's 1993 Fireblade cleanup [message #219144 is a reply to message #219142] Wed, 28 July 2010 22:43 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Drew Mate,

U need to get out more, it ONLY PLASTIC.

Glad u like. I must say I would have liked my first plastex repair to have been on a simple panel but WTF.

Got to give it a go.

SPal Grin

Be really pleased and amazed if it all works, Gonna go on ebay in min and buy dremil cause this stuff really is like concrete to trim and I need a decent cutting wheel.

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Re: SPAL's 1993 Fireblade cleanup [message #219213 is a reply to message #219141] Thu, 29 July 2010 23:13 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
SPAL wrote on Wed, 28 July 2010 22:32
Hi All

Plastex looks really soft, but drys like concrete si i dont really want to build up any more than i need to.

SPal Cool


Carried on building up missing sections now another "plastex" kit has arrived.

Used template from good side to mark position of air scoop, as I mentioned I didn't want to build up too much, but obviously have. Blush

index.php/fa/16492/0/

Roll on dremil,

Didn't get a chance to get plaster of paris as had to drop two bits to the finishers I forgot about, Der. Thumb Down

Head Race brgs turned up, (minus dust covers), can reuse top one, but bottom was destroyed getting off yokes, they say it may be four weeks b4 they are in stock, but with the engine finishing taking two weeks before I get a chance to rebuild this probably won't affect anything.

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Re: SPAL's 1993 Fireblade cleanup [message #219218 is a reply to message #219213] Thu, 29 July 2010 23:56 Go to previous messageGo to next message
Kermit is currently offline Kermit  UNITED KINGDOM
Messages: 15042
Registered: June 2003
Location: Leeds
(22) Giacomo Agostini
Just been catching up, looking good although don't envy the amount of filling you have to do. You've probably already considered this and its probably too late anyway but would any of the bigger gaps have been easier to fill by getting an old piece of fairing (you seem to have a few bikes so may have old beaten up panels lying around?) then cutting out a section of panel just undersize of the area to be filled then using plastex to join it to the blade fairing?

I used this technique on one of the NC30's lower panels joints (one to left = 100% plastex, one to right mainly old FZR fairing.....pic taken before reshaping them)
http://homepage.ntlworld.com/kernaldb/NC30/NC30_162_180706.jpg

Granted, that was a perfectly flat section of panel and yours looks anything but flat, but maybe small old sections of fairing can be coaxed to curve a little to almost the right share by heat prior to joining it on?
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Re: SPAL's 1993 Fireblade cleanup [message #219224 is a reply to message #219218] Fri, 30 July 2010 00:22 Go to previous messageGo to next message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi Kermit,

Unfortunatly I didn't have any other panels and thought that with the curvature of the fairing in that area it would be simpler (ha, did I say simpler Laugh ) to build up in layers.

I realised that only real realistic way of machining this stuff once dry is with dremil and grinding wheel.(which is on way).

In one respect its good that its so hard as even with really ruff sanding paper on sander it leaves a really fine finish.

Don't know if this will be realistic, but I would like to be able to complete without using any filler. (we'll see).

Sure that first coat of primer will point out any flaws.

On the hole (no pun intended) I'm really pleased, and amazed how well its going, especially when its saving hundreds of pounds in replacement panels.

SPal
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Re: SPAL's 1993 Fireblade cleanup [message #219239 is a reply to message #219224] Fri, 30 July 2010 10:36 Go to previous messageGo to previous message
SPAL is currently offline SPAL  UNITED KINGDOM
Messages: 835
Registered: June 2009
Location: London
(7) 125 GP Winner
Hi All,

Bright and early I went to hobbycraft with the intention of buying modelling clay to mould the missing top fairing air scoop with...................

FM, have you seen price of modelling clay!!!!! - Bought bag of Plaster of Paris for £3.00.

Mixed up and bunged (thats a technical term) into masked off apature.

index.php/fa/16493/0/

But even as I'm doing it I'm sure I've screwed up, can't get my head round getting from a female left handed non-symetrical shape to a female right handed symetrical shape.

I know i'll get it scanned in 3D and get a lazer cut die made Thumbs Up All for under a fiver (no expense spared) Laugh

Oh well see if I get insparation when plasters dried.

On a good note - dremil arrive so I can cut hole, even if theres nothing to put in it!

SPal

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