Thought it'd be good to continue this topic started on the old forum, on here too...
The idea was/is to have a standard RVF400 top fairing looking like an Endurance style fairing like the RC45's of the Suzuka 8 hours races.
I started off by chopping off a spare headlight in half and plugging one of the headlight holes; the inicial idea was to have this hole plugged with fibre glass, but the general consensus seems to be that this wouldn't last long when applied to a plastic fairing; in the end, plastic welding was the option I went for...

The headlight after the hacksaw treatment and the side cover being made after the chop:


Then a plug for the hole was made; using a bit of the recycled plastic off an unused recycling box, I cut it to the shape of the hole but slightly bigger. I ended up making 2 because the first one didn't come out like it should've, think it spent too much time in the oven and shrunk a bit...
This was it:


The second one was left in a preheated oven for no more than 4 minutes at 190 degrees, it was then removed and imediately placed over the unwanted half of the headlight so it would get its shape, I kept the hot plug on there (with oven mits on ) until it was cool again. This was then trimmed leaving a lip all around the plug to create a better base for the plastic weld to adhere to.


The plug was then plastic welded in place and left for a couple of days with some tape over it:


Then out came the bumper filler and over the plug it went, over that lip on the inside too, just to disguise it a bit:


3 layers of filler and some sanding later:


And that's how it was left in the old forum...
Following some question marks over the recycled bit of plastic used for the plug and wether it might not like the filler or the hot weather, I've decided to give the fairing a cheap 'make do' spray with some aerosol cans; this should make the thing a bit presentable for the next few months and will put the thing to the test; best thing to do before spending on a proper spray job...

This is where it's at, at the mo:


Been to Halfords today and got myself a spray can, premixed there and then with some 'Honda Fighting Red' paint, (Code R134). Hopefully by Sunday I'll have the thing painted and on the bike; will post back soon(ish). :D

Looking good!
Blended in very nicely.
Like you say, just have to see how it holds up to the test of time. Does the plug flex the same as the fairing, or is it stiffer?

Great looking job Speedy, can't wait to see it in a proper RED colour :D

re: the plastic welding....did you do this with a soldering iron or similar as while it might well be strong, if your in doubt about its strength then I maybe you should have used Pastex to bond the 2 plastic together as I know it bonds oem plastics with close to 100% strength and while that "recycle box" is no doubt made from un-determinal plastic it might well work with that too so bear it in mind if your unsure about the strength or as now the outer side is nicely filled, maybe you could use some in the inner joins?

Either way nice work and a well thought out moulding with the oven

Subscribed cant wait to see it finished.

My plans rarely go to plan and this one is working hard to sabbotage itself!
The "Red" paint came out a bit 'orangie'; having had a look at the Honda colour swatches twice, I'm convinced that the 'Fighting Red' (code R134) isn't the nearest match for the RVF red colour; R127 might be much better!
Was advised to give Honda a call and ask them for the proper code so it can be mixed into a spray can...
Can't promise it'll be done by this weekend, but I'll do me best! :)

The plug feels as solid as any other part of the fairing when tapping on it and it looks as though it's flexible too...
Erm, my bad! The method employed here was actually the plastex glue thing (the kind that comes in 2 tubes and has to be mixed), not plastic welding.

any pics of the orange nose cone lol

Yeah, I got a couple of pics but they don't really show the orange all that well, it's only when comparing to the proper red on the bike that it can be seen how much 'off' it is!
Called Honda this morning and the only code they have is for the white (NH196K - Ross White), no others, not even for the red???
Sod it; went back to the paint people and ordered a can of paint of the closest match and will see how it'll come out like...
It might not happen this week yet! GRRR!

im i dull an guliible as well as poor speller - or is it actually possible - to Subscribe to a thread - as in keep updated on a thread ??? - -

Lookin ace speedy ..

Click the check box at the bottom of the page where it says, options.(notify me when a reply is posted) when you post a reply.I think. :)

Looks like the old forum's gone.
There was a good sticky with the paint codes on. (Which I'm guessing you went by?)
Would be good if we could get it re-stickied on here.
Anyone?

...Would be a help to more than one :D