How to Repair a Broken Motorcycle Fairing?

If you own a motorcycle with a fairing (full, half, quarter, or wheel-based fairings), chances are you have had the near shock-to-death experience of replacement bodywork. If your motorcycle fairings have been badly damaged, it is best to fix them immediately.

Getting replacement fairings can be expensive; if possible, try to first repair your fairings.

If you prefer fixing your fairings, read this article to learn how to repair a broken motorcycle fairing.

A motorcycle fairing is a plastic or fiberglass shell that covers and protects the motorcycle's engine, frame, and rider from wind and debris. Motorcycle fairings can get damaged due to accidents, collisions, or daily wear and tear. When a fairing is damaged, it can compromise the safety and performance of the motorcycle and rider.

Here are a few reasons why you may need to repair a motorcycle fairing:

A damaged fairing can lead to structural problems, which can be hazardous to the rider. A cracked or broken fairing can cause the bike to become unstable and difficult to control, especially at high speeds.

The fairing protects the engine, frame, and rider from wind, debris, and other external factors. When the fairing is damaged, it can no longer provide adequate protection, leaving the bike and rider vulnerable to damage and injury.

Fairing is also essential to the motorcycle's overall appearance. A damaged fairing can affect the bike's aesthetics, reducing its resale value and overall appeal.

In addition, the protective paneling of the motorcycle fairings can become scratched over time. Broken fairings might decrease the resale value of your motorcycle. The most cost-efficient option is repairing the fairing by buying the required materials.

There are mainly two types of fairings: plastic and fiberglass fairings. Each type of fairing has a different yet easy repair process:

Acrylonitrile butadiene styrene (ABS) is often a component used in the construction of fairings and other motorcycle parts due to being scratch-resistant and offers protection from flying debris. It is a thermoplastic polymer widely used in various industries due to its excellent mechanical properties, toughness, and chemical resistance. It is a polymer blend consisting of three monomers: acrylonitrile, butadiene, and styrene.

ABS plastic is highly versatile and is used in applications ranging from automotive parts and toys to household appliances and electronic enclosures. Its high impact resistance, dimensional stability, and ability to withstand high temperatures make it suitable for various uses.

It is also relatively easy to process, allowing injection molding, extrusion, and other forms of processing to create complex shapes and structures. Its high surface finish and ability to be painted or plated make it a popular choice in the automotive and consumer electronics industries.

No, ABS has good strength and flexibility that will not crack due to minor impacts. However, it will crack if it is struck at high speed. 

Fixing a plastic fairing is slightly more difficult than a  fiberglass fairing. The following are ways you can repair an ABS plastic fairing:

• Using Fixing Solvent 
• Using ABS Cement
• Using the Plastic Welding Method

Methyl ethyl ketone is an easily accessible solvent that  melts the plastic and helps bind the parts back together.

• MEK
• Paintbrush
• Sanding Paper/Rotary Sanding Tool
• Tape
• Scratch Piece of ABS Plastic
• Any Container to Pour MEK (make sure not to get anything made up of ABS plastic)

• Pour the solvent into the container.
• Rub the surface with sandpaper to get rid of any broken edges. 
• Tape the broken plastic along the exterior to keep the fairing together.
• Dip the brush into the solvent.
• Apply the chemical solvent onto the interior of the broken plastic pieces. 
• Now apply the solvent on the scratched plastic pieces and press the parts together.
• Let the parts dry.
• Within half an hour, all of the plastic parts will be stuck together.

ABS cement is a black base liquid that can bind the soft and thin plastic parts together.

• Black ABS Cement
• Tape
• Sanding Paper/Rotary Sanding Tool
• Brush
• Small Container

• Rub the surface with sandpaper to make sure it is nice and smooth.
• Apply the liquid solvent on the edges of the broken pieces and stick them together.
• Tape the broken parts along the exterior after applying the solvent to the edges.
• Apply solvent on the upper side of the cracked parts.
• Leave it to dry.
• All parts should be stuck together after being fully dried.

It is possible to weld the plastic parts using a soldering iron or a plastic welding kit:

• Tape
• Soldering Iron
• Plastic Scrap Material
• Sanding Paper/Rotary Sanding Tool

• Tape the broken parts together along the exterior.
• Cut the 2 to 3-mm wide ABS strips to make little sticks for welding.
• Along the interior, use the V-Groove bit to bring the parts together.
• Take the plastic scrap piece and melt it from one end using the V-groove.
• Keep melting the plastic while placing it on the cracked or broken parts.

Watch this video for a better explanation:

• Tape
• Welding Kit

• Tape the parts together.
• Use sanding paper to rub down the broken parts and make them smooth.
• Use the metal knobs included in the kit to connect the broken parts.
• Turn on the welding machine, position the knob, and inject it into the cracked surface.
• Keep injecting the knobs until you fully cover the broken area.
• Make sure to leave a bit of space between every knob.
• Connect all the broken parts using the welding machine.

Watch this video for a better explanation:

Fiberglass is a high-quality and firm material often used in the construction of fairings.  It is easier to repair cracks on fiberglass fairings than on plastic fairings. Fiberglass, or glass-reinforced plastic or GFRP, is a composite material of a plastic matrix reinforced with glass fibers. It is a lightweight, strong, and durable material commonly used in various applications, including construction, aerospace, automotive, marine, and sporting goods.

The glass fibers in fiberglass are made of thin strands of glass, which are woven together to form a fabric-like material. This material is then impregnated with a plastic resin, usually polyester, epoxy, or vinyl ester. The resin binds the fibers together, providing the material with strength and rigidity.

Fiberglass has several advantages over other materials. It is lightweight yet strong and durable, making it ideal for use in applications where weight is a critical factor. It is also highly resistant to corrosion and can withstand exposure to harsh chemicals, making it a popular choice in marine and chemical industries.

Additionally, fiberglass is easy to fabricate and can be molded into complex shapes and forms. You can easily repair it, a significant advantage in applications where the material may be impacted or worn.

However, fiberglass can be brittle and may crack or break under extreme stress. It is also not as heat-resistant as other materials and may melt or deform at high temperatures. Additionally, fiberglass dust and particles can be hazardous to health if inhaled, making proper safety precautions essential when working with the material.

• Tape
• Fiberglass Cloth
• Brush
• Fiberglass Reinforced Filler
• Fiberglass Resin and Catalyst
• Mixing Sticks
• Body Filler (Bondo)
• Scissors
• Small Size Roller

• Using sanding paper, rub down the broken area of the fairings. Make sure there is no dust and grease on the cracked area.
• Tape the cracked parts along the exterior
• Apply fiberglass-reinforced filler on all cracked parts and let it dry.
• Then take the resin and mix it well with the catalyst based on the appropriate amount stated in the guide.
• Now cut the fiberglass cloth into pieces large enough to cover the crack. Cut at least a 30 to 40-mm wide strip.
• Apply the resin and catalyst solvent on the cracked parts.
• Place the fiberglass paper on the cracked sections and apply a good amount of solvent.
• Use the roller to bind the cloth and remove any air pockets.
• Leave it to dry.

If you wish to repair your fiberglass fairings, you need the following materials and must follow this process:

• Fiberglass Cloth
• Fiberglass Resin and Catalyst
• Roller
• Plastic Scrap Piece

• Cut the shape of the broken part on the plastic material.
• Mix the resin with the catalyst.
• Now apply the resin along the bottom and exterior of the fairing.
• Place the fiberglass cloth around the shape of the fairing.
• Pour the liquid solvent on the fiberglass cloth.
• Use the roller to remove any air pockets and smooth the fiberglass cloth.
• Leave it to dry.
• Remove the plastic parts that you attached to get the shape.

See this video for a better explanation:

Fiberglass resin will stick to ABS plastic but tends to not be a strong adhesive.

The image below shows how easily plastic can be removed from fiberglass cloth and resin:

Figure 1 When plastic is attached with fiberglass and resin.

Figure 2 Plastic easily removed from the fiberglass and resin. 

The difficulty of repairing a motorcycle fairing largely depends on the extent of the damage. Also, the type of material the fairing is made of. Repairing a minor crack or scratch on a fairing is relatively easy and can be done with some basic tools and materials. However, more significant damage, such as a large crack or break, may require more extensive repairs or a fairing replacement.

Repairing a motorcycle fairing typically involves the following steps:

• Clean the area around the damaged area to remove dirt, grime, and any loose pieces of plastic or fiberglass.
• Sand the damaged area to create a smooth surface for the repair material to adhere to.
• Apply the repair material, a plastic filler or fiberglass resin, to the damaged area using a putty knife or brush. Allow the material to dry completely.
• Sand the repaired area until smooth and level with the rest of the fairing.
• If necessary, paint the repaired area to match the rest of the fairing.

While the owner can do minor repairs to a motorcycle fairing, a professional should do more extensive repairs or replacement of the fairing. It is especially true if the fairing is made of fiberglass, requiring special expertise and tools. If the repair is not done correctly, it can compromise the safety and integrity of the motorcycle, which can be dangerous for the rider.

Make sure to clean and smooth the fairings after repairing them before applying paint. Different paints are available in the market, but it is best to choose one that provides protection.

You first need to remove the fairings from the motorcycle to repair it. It is not easy to repair the fairing if they are mounted on the motorcycle.

When repairing fairings, don't worry about the motorcycle paint when they are not mounted on the motorcycle.

After fixing the fairings, make sure to apply new paint to cover any old and new scratches due to repairs.

While riding at high speeds, debris such as dust, small rocks, UV rays, hot temperatures, and other elements are hitting the fairings. To better protect your fairings, you can either apply paint protection film and other ceramic coatings.

If you often tour cities on a sports motorcycle, get the fine glossy look of a ceramic coating.

If you go on tours or race on a sports motorcycle, it is best to use paint protection film.

While repairing plastic or fiberglass motorcycle fairings, some residue will be left, such as glue. Glue can stick to parts of the fairings and can be difficult to remove.

Use sandpaper and rub it against the parts with glue to help smooth the surface and remove glue stains. You can paint the fairings after removing the glue to give it a fine glossy look.

Repairing any motorcycle part is not too difficult if you know the right tricks. Motorcyclists love to modify their rides using aftermarket parts like fairings, saddle bags, crash bars, handlebars, sissy bars, padded seats, etc. Doing so can increase a motorcycle’s market value and give it a cool look.

If you have a motorcycle with broken fairings, try to fix the fairings by following the guide provided above.