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Discussion Starter · #1 ·
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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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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Discussion Starter · #5 ·
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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Discussion Starter · #6 ·
Pics are up

These are pics of the footpegs that I fabbed;





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







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











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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Looks like it's coming along great.
 

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Discussion Starter · #11 ·
Nice work man! The gray area on the fenders is that filling in places where there was no plastic?
Yeah there was a big hole in the one top part of the fender that someone tried to fix by riveting a margerine tub to the bottom, and there was a piece missing on the rear above the wheel. all the grey that you can see from the inside is just reinforcement.
 

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Discussion Starter · #13 ·
No, not yet... I havent had much time to work on them cause I've been on holidays and all over the place. As of now the inside is finished and I sprayed it with 3m rubberized asphault undercoating. The outside has been rough sanded, sprayed with adhesion promoter and skimcoated with the chemweld. I'm hoping to have the outside fine sanded tomorow and get a coat of finishing glaze on the rough spots. Then its just paint and reinstall... For the record, if you have any options other than this method I would pursue them as this is a painstakingly long process and if I was paying for the autobody fillers that I'm using I'm sure I would be well over $150 so far. The fact is that replacement fenders for the 86-89 350 simply do not exist, and I've seen want ads on Kijiji where people are offering up to $500 for plastics in just "decent" condition. Also, as I havent heard of anyone else trying this it's a toss up as to how long it is actually going to last. It might all crack apart and fall off the first time I ride it. Anyways I'll keep you updated.
 

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Yes, I would say a set of fenders in good condition would be almost impossible to find. I remember when those 4-wheelers first came out. The fenders crack very easy, especially if it's cold out. They have made big improvements in the plastics over the years.
 

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Discussion Starter · #15 ·
Well I got er almost all sanded down today, so with any luck I'll be able to skim coat, fine sand, and prime tomorow. I wish some company would take a mold of these plastics and make some new ones. I'm sure there are plenty of people out there with these bikes that would pay for new plastics...
 

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I'm sure there are plenty of people out there with these bikes that would pay for new plastics...
I agree, I see someone on different forums looking for those fenders all the time.
 

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yea but it cost alot to manufacture and to lower cost you have to sale more due to limited purchasers i dont see anyone jumping on it but if they had the forms you would think they would make some just to warehouse i guess we can all keep our fingers crossed
 

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yea but it cost alot to manufacture and to lower cost you have to sale more due to limited purchasers i dont see anyone jumping on it but if they had the forms you would think they would make some just to warehouse i guess we can all keep our fingers crossed
The biggest cost would be in building the mold, it wouldn't really cost that much to make the fenders. It's expensive to build molds, though.
 
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