Repairing broken fenders - Honda ATV Forum
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post #1 of 32 (permalink) Old 06-05-2010, 02:35 PM Thread Starter
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Repairing broken fenders

Just a heads up, I'm currently in the process or repairing both fenders on my 86 trx350. Both fenders are riddled with cracks and missing plastic in some places. Ive been welding the cracks back together without filler rod using just a torch and shaped chisels (under the guidance of the senior body shop tech at my work). Once all cracks are welded we will prep any plastic in the vacinity of a crack with a wire wheel and kent auto panel prep. The scuffed areas will be filled with Kent Chem Weld 45 (used as a filler) and then sanded to shape. I'll post updates as work progresses and might even get a few pics up
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post #2 of 32 (permalink) Old 06-05-2010, 07:10 PM
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On my first quad I did a lot of the plastic welding. My friend had the tool. For rods we used cut up pices of red honda fenders. It worked, it just was not very pretty. Sounds like you know what you are doing. Some before and after pics. would be cool.
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post #3 of 32 (permalink) Old 06-05-2010, 09:19 PM
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heck yea we are picture junkies im planning on something simular so please share all info
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post #4 of 32 (permalink) Old 06-10-2010, 12:45 AM
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Post some pics for the developments will be subscribing to this.
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post #5 of 32 (permalink) Old 06-10-2010, 04:57 PM Thread Starter
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Pics will be posted tomorow, progress is slow as I only get 45 minutes a day to work on it (my lunchour at work). So far I've just been working on the rear fender, All the cracks have been welded (mostly just to hold the pieces together while the chem weld dries) and the underside has had the epoxy applied. I used a fiberglass mesh tape where the holes where put masking tape on the outside over the holes so that the epoxy would take on roughly the shape I need. Like I said I'll take pics tomorow and post them. I also fabbed up some new footpegs as the ones that came on the bike were broken and welded with what looked like a hardsurfacing rod, and they had some sort of after market platform which were actually comfortable but made it almost impossible to shift or use the foot brake... I'll take pics of those tomorow as well.
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post #6 of 32 (permalink) Old 06-11-2010, 02:54 PM Thread Starter
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Pics are up

These are pics of the footpegs that I fabbed;

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This is my rear rack that I fixed today, will be painting it next week;

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And this is the rear fender so far (any shots from the exterior where you can see the grey epoxy was a hole);

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All cracks on the outside of the plastic will be ground out so that the final coat of chem weld will be invisible after paint.
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post #7 of 32 (permalink) Old 06-11-2010, 08:47 PM
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nice pegs really like the welding keep it up cant wait for the finished product
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post #8 of 32 (permalink) Old 06-11-2010, 08:53 PM
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Agree^^^^^^^^^^^
I can not wait to see the final product.

NEVER TAKE A SLEEPING PILL AND A LAXATIVE IN THE SAME NIGHT!
http://www.youtube.com/watch?v=Exbsw5ssn4I
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post #9 of 32 (permalink) Old 06-11-2010, 09:09 PM
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Looks like it's coming along great.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #10 of 32 (permalink) Old 06-13-2010, 09:13 PM
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Nice work man! The gray area on the fenders is that filling in places where there was no plastic?
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