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One of the tabs on my seat cowl broke off during my off road excursion. I repaired it with a product called Plastex.

The Plastex kit comes with a powder,a liquid, and a moldable compound.

I used the compound to make a mold of the opposite side tab which was still ok.The tabs are not mirror images of each other but the differences are only in the outer edge which made little difference.

The tab broke off flush with the outer edge of the hole in the tab. I took a small square file and filed back both sides of the remaining portion at a 45 degree angle(app) where the broken portion used to attach.

Next I fit the mold to the broken area and held it in place with some furnace duct seal.

I then placed a small layer of the Plastex powder in the mold and added a drop of the liquid. I continued this method until the mold was a bit over full.

Upon full cure, about 2 hrs, I removed the mold and filed the new casting to its finished size.

I used the white powder so that the repair would be easily visible for the photo. The 3 color kit I purchased has white, black and a milky clear powder.

If you look closely at the photo you can see the angle of the filing I did to get a good lap joint. (No thats not a place to get a good lap dance!)
Seeing as how I have no friggin idea how to post a picture here , you will have to click this link to see the photo.:
Click here for photo

Plastex has a website, click here for Plastex website

Hope this can help some of you to save a few $$. Ozzy.

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ANYBODY THINKING OF LOCTITE ON THE COWL BOLTS DON'T DO IT!!!!IT DESTROYS PLASTIC.DON'T ASK HOW I KNOW.

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Mines broke in the same exact place..... :-(

"Here, hold my trophy while I kiss your girlfriend."</p>
 
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When Mine broke I took it back to the dealer and said they need to replace it under my warrantee and I had a new one a week later

It's best to be presumed dumb than to open one's mouth and remove all doubt....</p>
 
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Hey Mikey....

Welcome to the world..

You may want to remove your Caps Lock it's like screaming and isn't always taken well. Just a FYI!

It's best to be presumed dumb than to open one's mouth and remove all doubt....</p>
 

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How did you guys break those tabs? You're hard on your stuff.

Not just a barbarian, a great barbarian!</p>
 

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I have no idea.

I'd never had the cover off. I didn't carry 12 packs of beer on the back when I had franky bolts, and Candy only rode on the cover 3 times.

Seriously though, I have no idea how it could have broke.

I have been known to say that the fasteners on the zx-12 are less than stellar, though. And I'll stick with that.

Love the bike, absolutely hate the fastening system.

Wanna see a well thought out fastening system, go look at a Duc or R1. It only costs the manufacturer maybe $30 to do it right with Dzus fasteners..... <img src=http://www.ezboard.com/intl/aenglish/images/emoticons/eek.gif ALT=":eek"> Sorry, pet peeve of mine.

"Here, hold my trophy while I kiss your girlfriend."</p>
 

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Debi's Wang has some of those shitty little push rivots on its plastic. Duc makes up for good fasteners with expensive service, huh?

Not just a barbarian, a great barbarian!</p>
 

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Let me dig through some of my stuff from school....the stuff that it is made from are home products....can't remember off the top of my head what they are.....when I find it I will post it.

Is that a Honda?</p>
 

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Ozzy, thanks for the info. I've broken plastic stuff like that before and thought it was unfixable. Yours looks good! Is the fixed tab just as strong as it was before being broken?

Thanks again.

"Take two beers and call me in the morning"</p>
 
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