Repairing cracked/broken shrouds on the 08 klr
Ok, like a large number of us, I have discovered that the shrouds on the
'08 KLR's are pretty brittle and prone to breakage. I found a good way to fix these with I will pass on. Bear in mind this is functional in nature and not necessarily the prettiest.
First, you are going to do all of the repairs on the inside of the shroud. Realign the cracked pieces and use thin Super Glue to hold them in place. Do the same for any small pieces which are broken off. I find that the "thin" SG works best as it will usually draw into the cracks via capillary action. The best "thin" SG can be purchased at any hobby store which caters to radio controlled cars/planes. I also use an accelerant to quick set the SG. This is also available at the hobby shops.
Second, you will need some fiberglass cloth, Gorilla Glue and disposable rubber gloves. The gloves will keep the glue off your hands. You can get the fiberglass cloth at any auto parts store. The Gorilla Glue at Wally World, Lowe's etc.
Third, cut pieces of the fiberglass cloth, about 2x2" and 1x2". Work in small areas about the size of the pieces of cloth. Start by covering an area the size of a piece of cloth with the Gorilla glue. Place the cloth down on the glued patch, overlapping both sides of the crack or break. Press the cloth down saturating it in the glue. It need be, add some more glue to saturate the cloth. You'll know you have enough when the cloth turns the color of the glue instead of white.
Fourth, keep adding glue and pieces until you get the entire crack/break covered. In areas of higher stress, like corners or the locator post, add more than one layer of the cloth and glue.
This will all set up over night. When it is hard you can trim off any stray strands of fiberglass.
Gorilla glue bubbles up as it cures, but if you "welded" the pieces first with SG it should not bubble through to the finished side.