1. Having trouble logging in? Try closing your browser and re-opening it. If that doesn't work, try a different browser or device. The site will be updated soon to resolve these browser issues.
    Dismiss Notice
  2. Dismiss Notice
  3. Want an XS400.com t-shirt? Go to the store to order. Limited sizes and quantities available.
    Dismiss Notice

81 XS400H – putting the Trusty back into Rusty

Discussion in 'The Garage' started by CaptChrome, Aug 19, 2021.

  1. Buddha

    Buddha XS400 Addict Top Contributor

    An electric knife cuts through that foam like a hot knife through butter.
  2. CaptChrome

    CaptChrome XS400 Addict

    Thanks @Buddha for the suggestion. I have heard those work well, but do not have one of those carving knives. I have used a serrated bread knife in the past, and that works well, but I am now forbidden from using kitchen equipment for my projects. I think that happened after I used a butter knife to pop out the tail lights on a VW New Beetle (perfect tool for that, BTW). I am also strictly prevented from using the oven for curing paint coatings or for the heating of castings to make bearing installation easier. The conditions I must work under are pretty grim.
  3. CaptChrome

    CaptChrome XS400 Addict

    Side cover repair-
    First off, a small hole was drilled at the very end of the crack. This is to help dissipate stress forces which tend to concentrate at the sharp point of a crack. If my repair fails, at least the crack should not progress further.
    Side Cover Repair1.JPG

    Next, the paint was sanded off around the crack in order to expose the raw material of the side cover. It looks to me like polystyrene plastic (the stuff plastic hobby models are made of). Even though I am not showing it, I did the same on the inside of the cover as well. I plan on reinforcing the crack with some fiberglass cloth, so I cut some small patch pieces and also pulled some glass fibers out in order to stuff in the hole I drilled.
    Side Cover Repair3.JPG

    I think there are three glues that might work for this repair – plastic hobby model cement or all-purpose plumbing pipe glue that can be used for ABS pipe, polyester fiberglass resin, and epoxy resin. The first two work by softening the styrene in the cover and chemically “weld” to the parts. The epoxy resin relies on mechanically attaching itself to the part. At the moment I have some all-purpose pipe glue, so that is what I am going with. I put glue in the crack and over the exposed plastic, placed the fiberglass cloth patch in the wet cement and then completed wet out of the cloth with a bit more cement where needed.
    Side Cover Repair4.JPG

    Some glass stands and glue were jambed into the hole and then the patch placement was repeated on the inside. However, I used two fiberglass patches for added strength on the inside where the extra bulk won’t be noticed.
  4. CaptChrome

    CaptChrome XS400 Addict

    I put some polyester body filler on the side cover repair.
    Side Cover Repair5.JPG

    The cover is now sanded and ready for some warmer weather so that I can paint it. Once Trusty Rusty leaves the shed, it will spend its life outside, so something will be needed to keep the rain, snow, debris and UV rays off of it. I have some leftover marine canvas so I took some measurements for a fitted cover, templated up some panels and cut them out of the fabric...
    And I have started on stitching all of the pieces together.

    This work needs to be done with bare hands and with the temperatures out in the shed, I am having to take lots of breaks to warm up. I figure I still have an hour or two of work out there in order to finish it off.
    Dean grigson likes this.
  5. JPaganel

    JPaganel XS400 Addict

    "ABS plumbing glue" is really just some ABS in a solvent. It works well on motorcycle plastic, and can make good repairs with fiberglass.

    I am not sure what the all-purpose plumbing glue is, but there really shouldn't be any issue with it either. Motorcycle plastics are ABS, just like drainpipes. Only pipe ABS is dyed black.

    My preference is ABS glue over pretty much all the other stuff. I've filled cracks and even built up missing pieces out of it.
    CaptChrome likes this.
  6. CaptChrome

    CaptChrome XS400 Addict

    @JPaganel - thanks for the personal experience with ABS glue. I have not used it, but will definitely try it out the next time I have a go as fixing some plastic.
    JPaganel likes this.
  7. CaptChrome

    CaptChrome XS400 Addict

    I haven't gotten much done this week other than finishing the bike cover.

    The weather warmed for a day and I also managed to get some primer on the side cover repair and am looking for the next window to do the top coats. Just chipping away at it. I do have a pretty busy schedule the next few weeks, so I will see if I can do some small bits to get them off of the list.
    Last edited: Feb 1, 2023 at 6:39 PM
    JPaganel and Dean grigson like this.

Share This Page