Tail Plastic


Stock Kawasaki AR80 tail plastic

I plan on reusing the AR80's plastic tail piece, but it needed to be cleaned up and modified for my new tail light.

Stock Kawasaki AR80 tail plastic

Overall the plastic was in good structural shape.

Stock Kawasaki AR80 tail light mounting holes.

Except for this hole.  I don't think that was the stock hole for the stock tail light.  I'm not sure why the PO mangled it so badly.

Stock Kawasaki AR80 tail light mounting holes.

No biggie.  I planned on filling the stock mounting holes anyway because my taillight only needs a single small mounting hole.

JB KwikWeld Epoxy

I bought some JB KwikWeld Epoxy to fill the old holes.

Duct tape.  What can't it do?

I put some duct tape over the old mounting holes.

Scuff it.

And scuffed up the inside plastic to give the epoxy something to hold on to.

Mmmmm.  Generic cinnamon toast crunch.

Delicious

JB KwikWeld Epoxy

Once mixed I liberally slathered the epoxy over the old mounting holes.  I don't really care what it looks like on the inside so I wasn't particularly careful.

JB KwikWeld Epoxy

Once dried I pulled the duct tape off to see what I had.  Kind of a freaky Mickey Mouse.

JB KwikWeld Epoxy

After a bit of sanding I had this.  Nice an smooth.

What is this for?

Except for this . . . thing.

Bondo and JB fills all.

I used some body filler to fill it in, and then sanded it smooth.

AR80 tail plastic

There were a few other places that needed some work.

AR80 tail plastic

A little body filler and sanding took care of those as well.

Rust-oleum Plastic Primer

After things were fairly smooth it was time for some primer.  I grabbed some Rust-oleum Plastic Primer.

Rust-oleum Plastic Primer

Rust-oleum Plastic Primer

Rust-oleum Plastic Primer

It will definitely need some more sanding and prep before final paint, but it looks good for now.

"Custom" Kawasaki AR80 tail plastic

Finally, it was time to mount my new tail light.

"Custom" Kawasaki AR80 tail plastic with pimiento jar tail light

Installed.

"Custom" Kawasaki AR80 tail plastic with pimiento jar tail light

One hole.  Nice and simple.

"Custom" Kawasaki AR80 tail plastic with pimiento jar tail light

"Custom" Kawasaki AR80 tail plastic with pimiento jar tail light

"Custom" Kawasaki AR80 tail plastic with pimiento jar tail light

I think it looks pretty good.

5 comments:

  1. Off topic, but just a little: you'll probably discover that your rear monoshock has lost its mojo, errr damping powers. Likely it has suffered a blown seal. You might consider alternatives: http://typobargains.com/mono_shock_absorber.html
    This guy used an Aprilia RS125 shock: http://www.2strokeworld.com/forum/index.php?topic=14857.msg122725#msg122725

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  2. When research showed that most of the replacement shocks cost more than I originally spent on the whole bike I decided to stick with the (cleaned up) stock one. At least for now.

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  3. I fear this project has fallen lower and lower among your priorities! Any progress? I rode my AR80 to a scooter rally this past Saturday, its inaugural ride. Unlike its last three trips to the dynamometer, it didn't blow up or shower the road with irreplaceable parts. I was surprised.

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  4. Great job, You are providing good knowledge. It is really helpful and factual information for us and everyone to increase knowledge. Continue sharing your data. Thank you. Welding Machine Price In India

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