Fibreglass Motorbike Hugger Repair

[johnsmith222]

Hello everyone,

Unfortunately the hugger on my motorbike has become damaged at one of the bolt mounting points. All other mounts are intact. Although I have extensive car repair experience, I have always kept my distance from bodywork.

The bike in question is a ZX9R and brand new huggers are available for £120. This might be the option I end up going down as I plan to do a semi-restoration this or next winter.

There are plenty of fibreglass repair videos on youtube, but I am finding they are mostly repairs which are holes or cracks in the middle of a panel, which look easier to repair.

I was wondering if you had suggestions as to the best way to repair this damage. I would consider putting it into a bodywork place to repair, but I imagine it would cost as much as a new hugger anyway.

Note, the cracks in the green paint are just finish cracks and these sections are structurally solid.

I was thinking of trying something with a kit like this: https://www.toolstation.com/big-boy-fibre-glass-re...



Thanks for your help everyone

https://imgur.com/a/NoTEswu

Edited by johnsmith222 on Saturday 7th June 10:41

Edited by johnsmith222 on Saturday 7th June 10:43

[Belle427]

Personally I would just buy a new one, edges like that are always difficult to repair well.
Im no fibreglass expert but if you did tackle it maybe it needs a piece of metal shaped and bonded in underneath so to speak so it give it some structure to work to first.

[LennyM1984]

Aluminium tape, a few layers of cloth, and then some fibreglass filler/gelcoat (with wax) to finish.

I've done quite a lot of fibreglass repairs on my race car but for £120, I'd probably just buy a new one

[johnsmith222]

Belle427 said:

Personally I would just buy a new one, edges like that are always difficult to repair well.
Im no fibreglass expert but if you did tackle it maybe it needs a piece of metal shaped and bonded in underneath so to speak so it give it some structure to work to first.

I think you're probably right that I'm best cutting my losses and replacing it.

The bike needs a bit of minor restoration work that I'm planning to do sometime soon (blasting and powdercoating of wheels and swingarm) so bodging it probably wouldn't suit.

Thanks.

[johnsmith222]

LennyM1984 said:

Aluminium tape, a few layers of cloth, and then some fibreglass filler/gelcoat (with wax) to finish.

I've done quite a lot of fibreglass repairs on my race car but for £120, I'd probably just buy a new one

Thanks Lenny. I might have a go to see if I can at least hold it temporarily. I'm planning a semi-restoration soon as the wheels and swingarm need powdercoating so would be best to replace it to go with these improvements.

thanks again.