Author Topic: K Bike Fairing Repair  (Read 16377 times)

Offline The Mighty Gryphon

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K Bike Fairing Repair
« on: September 27, 2016, 11:43:09 AM »
Last July I dropped my K75RT in Nebraska breaking up the right side lower fairing among other things.  Since I can't find a usable panel to replace it, I decided to repair it.  This thread will document the job.  I hope that in the future it will prove useful to others who find themselves in the same situation.

First thing was to clean off the mud and epoxy the lower mount back on.

  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #1 on: September 27, 2016, 11:53:45 AM »
Next, I used super glue and zip catalyst to attach the broken part to the rest of the panel.  Here is where the hefty molding with all it's glass fibers comes in handy.  By pushing the broken parts back together and getting them in alignment put a few drops of super glue on the joint and spray with the kicker.  Make absolutely sure everything is perfect because once the glue kicks there is no turning back.

Before I glued up the parts I had to break off a couple bits that were preventing proper alignment.  No big deal, It's more important to have everything straight.  The glue will hold everything while you make the repairs.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #2 on: September 27, 2016, 11:57:36 AM »
Once the parts were attached I used an 80 grit sanding disc to remove the paint and rough up the back side of the panel to prepare it for the fiberglass that will provide the structural strength. 

  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #3 on: September 27, 2016, 12:12:18 PM »
The strength of the repair comes from fiberglass applied to the back of the panel with polyester resin.

The fiberglass I use is a lightweight 2 oz.  2" wide tape.  It is thin enough to be easy to work with and the edges don't get all messy.  2" is wide enough to work well without being clumsy.  I get the stuff I use at hobby shops where they sell it for guys building large flying model airplanes. 

Cut all your pieces and have them ready to go.  I use about 2or 3 layers of cloth to get a reasonably strong repair without building up the surface too much.

Mix up the resin, about 1 oz. is about right for most repairs.  12-14 drops of catalyst is about right to get a decent amount of working time.  Paint the resin on with a chip brush and then lay on the fiberglass pieces one at a time working resin into them until they are clear and you can't see the weave of the glass fibers.

Don't worry too much about cloth extending beyond the edge.  You can trim it off with a razor blade after the resin sets up hard.  You do want to make sure the cloth is well attached to the panel with no bubbles.  Once everything is saturated and there are no bubbles and the cloth is all where it needs to be clean the brush with acetone and clean up.  I let everything sit over night to make sure the resin will be set up hard before the next step.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline TrueAce

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Re: K Bike Fairing Repair
« Reply #4 on: September 27, 2016, 01:39:59 PM »
Nice presentation, Mighty Gryphon! You make it seem so clean and easy, like you do it all the time on sail boats or something! Was the damage from your record-breaking Iron Butt tip over? Somehow my fiberglass projects don't turn out so neat! :2thumbup:
  • Florida
  • '85 K100GS, '85 K100RSSC,', '94 K1100RS,'10 S1000rr,'14 Ural Sidecar, '15 R Nine T

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #5 on: September 27, 2016, 02:06:11 PM »
Yes, Ace, it was from when I pulled off the road on my Iron Butt run and laid her down.

Fiberglass repair isn't all that hard if you have all the stuff ready and are careful to mix the resin properly.  One thing I didn't mention is the need to accurately measure the resin.  I use small paper cups.  I take an once of water and pour it into a cup to see where the level is.  Then I fill a second cup to the same point and add 12-14 drops from the tube of hardener catalyst.  A lot of fiberglass problems come from resin that never hardens or "kicks" too fast.  Never measure and mix by eye.

Another thing is to do all the glassing at one time.  Glass that is laid up in one go will be stronger than doing it in two or three applications.  A lot of additional prep is needed when you do a second application. 

I didn't mention it, but I always have a box of those blue nitrile gloves close by and will change them whenever they get any sticky stuff on them.  Clean gloves make everything easier to handle.

The structural stuff is really the easy part, the cosmetics are where you need to take your time.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline jaxon

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Re: K Bike Fairing Repair
« Reply #6 on: September 27, 2016, 02:08:40 PM »
Handled it like a boss.

Cringe. fix. ride.
  • Indiana
  • '92 K75S, '17 R1200GS LC
--
This space for rent

Offline TrueAce

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Re: K Bike Fairing Repair
« Reply #7 on: September 27, 2016, 02:11:42 PM »
Good pointers, Gryphon, I need more practice. :euro
  • Florida
  • '85 K100GS, '85 K100RSSC,', '94 K1100RS,'10 S1000rr,'14 Ural Sidecar, '15 R Nine T

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #8 on: September 27, 2016, 02:23:28 PM »
Stay tuned, the next installment should be coming in a couple of days.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline Martin

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Re: K Bike Fairing Repair
« Reply #9 on: September 27, 2016, 02:53:24 PM »
 :2thumbup: So obviously you couldn't find a replacement, I'm amazed I thought eventually you would inundated with them, especially with all the café scrambler projects. Looking on with interest I have only ever done small glass projects, your write up is encouraging. :popcorm
Regards Martin.
  • North Lakes Queensland Australia
  • 1992 K75s Hybrid, Lefaux, Vespa V twin.

Offline herseyb

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Re: K Bike Fairing Repair
« Reply #10 on: September 27, 2016, 04:02:46 PM »
you got a thread about dat dere iron derrier ride?
  • Brooklyn
  • '93 K1100RS

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #11 on: September 27, 2016, 04:44:13 PM »
The Iron Derriere ride wasn't something I really want to remember. 

1524 miles in 23hrs 40min.  Heavy rain all the way across Nebraska, Iowa and a chunk of Illinois.   45 to 50F temperatures at night across Indiana, Ohio, Pennsylvania and New York.  The aforementioned drop on a farm road construction detour in Nebraska.   

Would have been a nightmare but for Ilsa my trusty K75RT.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline herseyb

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Re: K Bike Fairing Repair
« Reply #12 on: September 27, 2016, 05:09:02 PM »
Roger that.  I was just curious because my only drop *knock on wood* was pulling off of a road during a long heat stroke inducing ride.  I was going so slow that I was just able to step off the bike, but as I pulled onto the gravel shoulder I suddenly was pulling too much front brake...  slid right out from under me.


  • Brooklyn
  • '93 K1100RS

Offline TrueAce

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Re: K Bike Fairing Repair
« Reply #13 on: September 27, 2016, 06:29:44 PM »
Mighty Gryphon is too modest.......he did that run AFTER about a 4000 mile non-stop loop out West wandering around the desert spaces like the Israelites! A real Iron Man! :clap:
  • Florida
  • '85 K100GS, '85 K100RSSC,', '94 K1100RS,'10 S1000rr,'14 Ural Sidecar, '15 R Nine T

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #14 on: September 28, 2016, 01:00:49 AM »
Actually I had done 5500 miles before the start.  I'm only trying to keep up with the mighty Ace.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #15 on: September 28, 2016, 11:01:57 PM »
Ok, the glass work has had a day to harden.  The repair is now as rigid as the original part. 

I spent about 15 minutes today cleaning up some of the resin I slopped on the front side and along the edges.  Was able to scrape most of it off with a razor blade and did a little bit of sanding with a bit of 80 grit.

On the back side I trimmed off the glass that overhung the rib that the gasket attached to with the razor blade.   Then I spent about five more minutes knocking down any fibers that stuck up and smoothing down the surface with that 80 grit. 

The structural part of the repair is pretty much done now, next step is working on filling in the damage on the front.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline RDNZL

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Re: K Bike Fairing Repair
« Reply #16 on: April 23, 2017, 11:32:16 PM »
....I just got here and found this thread. I've got a similar repair on my upper fairing and was hoping for more follow-on for the front side work....
  • Bainbridge Island, WA
  • 96 K1100

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #17 on: April 24, 2017, 01:16:29 AM »
Welcome to the knuthouse!  Can you pot a photo or two of your damage? 

I'm sorry I didn't get further into the repairs I was documenting,but at the time there were some problems with uploading the the photos and I just finished the job I was working on to get my bike back on the road, and didn't spend time with the camera. 

Basically, the procedures on the back side are used for the front.  The only thing to remember is that you are going to be finishing the surface with Bondo to make something that can be painted and look nice.

To accomplish that you will use the disc with the 36 or 80 grit to grind down far enough that two layers of the glass cloth will be far enough below the finished surface to allow for a skim coat of Bondo filler on top. 

Shaping and fairing in the filler is fairly easy.  The secret is to use a block for all sanding up to the final coat of filler and to use a sawtooth edge spreader for the first coat of filler. 

The idea of the sawtooth spreader is that it greatly minimizes the amount of filler you need to remove to get the rough shape you are looking for.  The spreader is the square plastic one you get at the hardware store for spreading tile adhesive.  When you put the filler on, you will only be sanding off the very top sof the V's to shape down to the desired form.  Then you go back with a regular spreader to fill in the remaining grooves.   The shaping is done with 80 grit to knock things down quickly. 

When sanding, avoid going along or across the curve of the surface.  Rather, go at a 45 degree angle sanding from both diagonals.  Pieces of radiator hose and chunks of wood can be used for shaping details like grooves and concave surfaces.  Always use the longest strokes possible, concentrating on keeping the pressure on the surface as uniform as possible all the way through the stroke.  Avoid short back and forth strokes as much as possible. 

When you get close,using 220 grit, light dusting coats of black spray paint will help highlight high and low spots.  Make sure all your filler gently fades into the surrounding surface without any sharp edges.  Those edges are goingto show through your finish coats.  Take your time, you will spend many times as much time looking at the repair than you will ever spend getting it shaped right.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline RDNZL

  • Curious
  • Posts: 7
Re: K Bike Fairing Repair
« Reply #18 on: April 26, 2017, 05:59:15 PM »
Left side:
  • Bainbridge Island, WA
  • 96 K1100

Offline RDNZL

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  • Posts: 7
Re: K Bike Fairing Repair
« Reply #19 on: April 26, 2017, 06:03:33 PM »
Right side:
  • Bainbridge Island, WA
  • 96 K1100

Offline The Mighty Gryphon

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Re: K Bike Fairing Repair
« Reply #20 on: April 27, 2017, 12:42:49 AM »
Had the same problem with Moby Brick when I decided to do the domino thing in the garage last year.  Fortunately it was only on one side on my bike so I only had half the work.

First, is the windshield unbroken at the tabs that mount it to the "horns" on the fairing?  That is critical to getting the parts aligned for the first part of the repair.  You might have to break down and get an undamaged one.

Second, install the windshield, getting all the screws installed in the broken pieces.  This will get things aligned so the windshield will go in after the repairs. 

Third, using a straight edge, reflections of fluorescent light tubes, eyeball, etc, get all the parts in exactly the place where they should be.  Don't rush, this is the most critical part of the job.  If there is a bit of spring in them, you might need to hold them in position for the next step.  Try not to be in that situation though, as you will then require a helper.

Fourth, with the parts perfectly aligned, saturate the fibers of the damaged area with CA(super glue) and then give it a shot of catalyst spray.  This stuff can be had at any hobby shop that cater to the guys who build R/C airplanes.  This will immobilize the broken parts in position so you can do the rest of the repair.

Do one break at a time, making sure that you have the parts perfectly aligned.  Did I mention you should have the parts perfectly aligned?  Once they're glued, it gets VERY hard to adjust them.  With the windshield attached during this part of the job you can be sure that if all else fails, at least you will be able to attach it again when everything is done.  The material the fairing is made of is very conducive to this repair technique.

A trick that the model guys use that may help to get stronger glue joints is to dust a little baking soda into the damaged area as a filler, working it in with a cheap natural bristle chip brush before you apply the super glue. 

At this point don't be worried about glass fibers sticking up all over the place.  You are going to grind them all down for the next stage of the repair. 

When all the breaks are glued up look at your alignment.  Are the surfaces straight and in alignment everywhere they should be?  Make sure everything is perfect.  This will be your last chance to get it right.

If there are any repairs that aren't perfect, you have a chance to get them there by soaking the joint with acetone applied with a small paint brush.  Paint it on a little at a time keeping the area wet without the acetone getting all over the rest of the fairing.  After a few minutes, the super glue will have softened enough to allow you to GENTLY bend things into alignment.  You will have to hold them there until the acetone evaporates or at least keep going back every couple of seconds to straighten things up.  When the acetone finally evaporates(about 20 minutes) give the joint a second shot of super glue and catalyst.

At this point all the broken pieces should be in perfect alignment and ready for the fiberglass.  The fiberglass is necessary to restore the full strength of the fairing, and to prevent cracks forming at the breaks after all the work is done.  I like to use a very light 3/4 oz. cloth tape about 4" wide for my repairs.  The tape with it's bound edges is very easy to work with.  I get it at the airplane hobby shop where I get the Super Glue and catalyst.

Two layers go on the top and at least three on the back side of the repair(use more if you can back there, you can't make it too strong). 

First step in this phase is to get a sanding disc for a power drill.  The old school drills with cords are the best.  80 grit is about right.   Gently grind away the front surface with the disc to a depth of about 1/16".  Do the full width of the "horn" at least 5 inches long on the horn.  This is to allow you to stagger the 4" wide tape so that both edges of the tape are not on top of each other at the edges of the repair.  Make sure the area you are grinding is smooth with no dips, high spots, or ridges.  Any major dips in the surface will result in a weaker spot from too much resin for the glass.

When the grinding is done vacuum up all the dust.  Cut two pieces of glass tape and check where they will be going on the repair.  Trim them to fit, and mix up a small amount of polyester resin per my instructions in the other thread.  Paint it on with a chip brush and lay on the two pieces of glass tape one at a time working the air out of each.  You have about a minute to get each piece down.  Don't try to get the glass to bend over sharp corners.  It won't do it.  Just get it nice and flat on the repair area.

As soon as you have the glass in place clean the brush with some acetone and wait for the resin to cure.  If you mixed it right, that shouldn't take more than 10 minutes. 

Repeat for each of the broken areas, working from the bottom of each horn to the tip.  Be GENTLE with the sanding disc.  The parts can still be knocked out of alignment.  When all the breaks have been covered on the outside, go to the back and remove the windshield and glass the back side.  This will be a bit easier in that you only need to rough up the surface with the 80 grit to make the resin bond better.

Again, do one break at a time, cut your fiberglass to fit and let the resin cure before moving on to the next break.  I am going to recommend that you only use three layers on the back side, because the resin might cure before you can get all the air out of more layers.

I would also recommend that after each repair on the back side you make sure you can get the windshield back on with all the screws.

Once the glass work is done it's time to do the bondo and surface prep for the paint.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline RDNZL

  • Curious
  • Posts: 7
Re: K Bike Fairing Repair
« Reply #21 on: April 27, 2017, 09:27:27 AM »
Wow! Thanks for the info. I'll keep you abreast of the progress.
  • Bainbridge Island, WA
  • 96 K1100

Offline Rcgreaves

  • ^ SuperNatural Motobricker
  • Posts: 974
  • "I'd rather be flying, but this will do nicely"
Re: K Bike Fairing Repair
« Reply #22 on: August 21, 2017, 11:51:57 AM »
Welcome to the knuthouse!  Can you pot a photo or two of your damage? 

I'm sorry I didn't get further into the repairs I was documenting,but at the time there were some problems with uploading the the photos and I just finished the job I was working on to get my bike back on the road, and didn't spend time with the camera. 

Basically, the procedures on the back side are used for the front.  The only thing to remember is that you are going to be finishing the surface with Bondo to make something that can be painted and look nice.

To accomplish that you will use the disc with the 36 or 80 grit to grind down far enough that two layers of the glass cloth will be far enough below the finished surface to allow for a skim coat of Bondo filler on top. 

Shaping and fairing in the filler is fairly easy.  The secret is to use a block for all sanding up to the final coat of filler and to use a sawtooth edge spreader for the first coat of filler. 

The idea of the sawtooth spreader is that it greatly minimizes the amount of filler you need to remove to get the rough shape you are looking for.  The spreader is the square plastic one you get at the hardware store for spreading tile adhesive.  When you put the filler on, you will only be sanding off the very top sof the V's to shape down to the desired form.  Then you go back with a regular spreader to fill in the remaining grooves.   The shaping is done with 80 grit to knock things down quickly. 

When sanding, avoid going along or across the curve of the surface.  Rather, go at a 45 degree angle sanding from both diagonals.  Pieces of radiator hose and chunks of wood can be used for shaping details like grooves and concave surfaces.  Always use the longest strokes possible, concentrating on keeping the pressure on the surface as uniform as possible all the way through the stroke.  Avoid short back and forth strokes as much as possible. 

When you get close,using 220 grit, light dusting coats of black spray paint will help highlight high and low spots.  Make sure all your filler gently fades into the surrounding surface without any sharp edges.  Those edges are goingto show through your finish coats.  Take your time, you will spend many times as much time looking at the repair than you will ever spend getting it shaped right.


OK Time to dig into my fairing and Gryph clearly has the method.  I have more to do like the tank but the fiberglass bits are restoreable methinks... I'm an R/C aviation modeler too so these materials are familiar. 


What about paint?  Ie primer and a USA source for Code 616/204 Columbia Silver.   Thanks in advance

  • Livingston in Southwest WI. USA-"With the good earth all around."
  • 94' K75S, 85' GL1200 Aspencade, 96' VFR750F, 01' GL1800. Restoring: 95' K1100RS, 83' R80RT NEW: Motorvation Formula II
Doing “better than I deserve"

Offline K75riderilm

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  • Posts: 6
Re: K Bike Fairing Repair
« Reply #23 on: August 21, 2017, 01:02:02 PM »
I have an entire K75rt fairing that needs a new home. It's in good shape other than the paint isn't great.
  • Wilmington, NC
  • 93 K75rt

Offline Rcgreaves

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  • Posts: 974
  • "I'd rather be flying, but this will do nicely"
Re: K Bike Fairing Repair
« Reply #24 on: August 21, 2017, 03:13:56 PM »
Hi , so your handle ends in ilm??? Industrial Light and Magic?  I love Mom?


So my bike is an S model and though RTs are cool.... :neener:  Not cool enough....


Perhaps post to the FS For Sale Forum...Very desireable model, search Ebay for comparables... Hard to get fairing.. Good Luck.
  • Livingston in Southwest WI. USA-"With the good earth all around."
  • 94' K75S, 85' GL1200 Aspencade, 96' VFR750F, 01' GL1800. Restoring: 95' K1100RS, 83' R80RT NEW: Motorvation Formula II
Doing “better than I deserve"

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