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Today I got Frankenbike's plastic grafting in place. Trimmed the pieces and got s pretty good fit, then bonded with CA, CA with baking soda, a bit of heat melting, and JB plastic epoxy. Fits very good and the dimensions are correct.
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Any more pics or steps in this process?
It looks good.
Thanks, I appreciate the compliment...
Slow progress as my right hand is in splints following my accident, but I'll be posting updates. Sanding it is tedious, but it's almost ready to start priming. I've been filling a few little rough spots... if you take scrap pieces of fairing and, literally, light them on fire, they melt and start to drip, which works great as a filler. Seems to burn at pretty low temperature...I cut a strip of material so I can hold one end while the other end burns like a candle. Again, hard to do with one hand lol, but I have time
 

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Acetone applied sparingly with a small brush can also help “blend” in some cracks. I’ve only tried this once so YRMV but it was helpful.
Thanks! I've heard of that also but haven't tried it. I've got plenty of spare plastic to experiment with though.
 

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What kind of paints are you using?

I've had fair luck with the Bulldog adhesion promoter and then Rustoleum paints over that.
Currently working on the Gen-1 project side panels and rear fender using Bulldog as the base and then Rustoleum 2x Real Orange Gloss, and will finish with 2x Clear Gloss.
I've been using a Duplicolor sandable filler in red and Rustoleum 2X Ultracover. Probably lots of better things out there but this works and has been very durable. The final color is very close to the red plastics.
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I went and did some highway miles with my new 2022 klr. 1,300 miles so far. It really has amazing torque. Cruised just fine at 70mph. Comfortable ride never got sore. I'm a new rider and every day I have a different opinion on what tire I want next. Mostly road driving but love gravel. The D750 are not great on gravel. Trying to decide between shinko 705 and the Bridgestone battlax.
I've been running 705s the last year, they're good as a 70/30 tire, I would say most adventure conditions except mud. They wear well also. I used Conti Escapes before that and they were similar in performance, though I like the 705 tread patten more and they're a good price. The Battlax has great rubber compound, but I've only used them as a street tire.
 

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Looking damn good there - KLR04!

Can you show us how you're working that dash?
I have a challenge in deciding how best to fit the Trailtech Vapor into the gap behind my black cowling.
Super simple.. just a flat piece of abs. I had some edging material to finish it.
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Now I'm working on a windshield. I bought a used cruiser windshield off a guy for $10, and I'm trying to chop it down into a Parabellum style. It's working out really well... this is the first cut, I'm probably going up narrow it a little..
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Got my knock off windshield pretty much finished today, trimmed it down a little and smoothed out the edges, then lined up the mounting holes. This is the second windshield I've hacked, first one was destroyed in my recent crash.
Here's the new one...
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and the first one I did, which I really liked...
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I don't recall reading previously anything about your bike needing a crankshaft replacement.
And I can't see anything amiss in the current pic, as that must be the New Crankshaft.

So may you show us, tell us what is wrong with your engines crankshaft?

I would like to see this failure & repair in its Own Thread,
In this section, 1987 through 2007 KLR650 Wrenching & Mods If possible?
Ohhhh it's a bit of a story... simplest explanation is engine damage secondary to an accident, not a failure. The woodruff key for the stator got crushed in the slot, literally no way to remove it (I tried everything to the point of damaging the crankshaft). No idea where the best section to post is, but I'm open to whatever a moderator would like.
 
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