How To: DIY Track Fairings from OEM Plastic - ZX6R Forum
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post #1 of 17 Old 10-09-2013, 03:50 PM Thread Starter
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How To: DIY Track Fairings from OEM Plastic

So, being that I have more time than money, I decided to buy a set of OEM nose and side plastics for my 04. After my rainy wreck at Road Atlanta I did not want to have to repair my stock orange fairings a third time due to a track day low side .

I have been saving up this thread for a while so everything is in it. If you have any questions hit me up. I know it would be SUPER easy to buy track plastics and just paint them...but hey...when you've got time, why spend the money??
The nose AND side plastics cost me 150 shipped from Sean on here. i spent about $40 total on JB weld and bondo and body filler, and $25 for my belly pan decals (they'll be in early next week and will update with pics.)

Enjoy


Nose from SSGSXRZX6R (Sean)


Piece was broken (I knew prior). Fixed.



Primed


Fairings came in from Sean. USPS broke this piece. I filed a claim and got my money back a week later for the price I paid Sean for.



Fixed said fairing. Heat molded some plastic and JB welded it. I'm going to add the triangle piece later



After primed white. Used Plastidip blaze orange. About 3 coats total.


Applied one coat of clear gloss. Makes Plastidip easier to clean and handle


Filling in the light openings for track nose.
Using some plastic from X-Ray film cartons. (My dad works in that field, has
plenty. It's really good to work with. Soft enough to easily mold with heat
gun)


Cut out the stencil. Notched spots for tabs (for securing to backside)



Use heat gun, mold the curvature.






Tabs secured with JB weld. Will probably do a ring of plastic weld just to
be super secure


Filling in the front side with a layer of bondo body filler. Slathered on
like cake batter.


Let cure for 12 hours. Used electric sander to smooth out and level the
filler with the nose plastic


Yeah I ruined the Plastidip. But hey, it peels off and I can just redo it no
problem later.

Need to bondo fill the remaining smaller cavities



Now to fix the broken chunk I couldn't find after reattaching the bigger
broken part


Using a skinnier long piece as a backbrace on the inside


Now to make this more "track compliant" by cutting the bottoms in half where
I will then attach tabs to the tops and then drill holes and rivet DZUS
fasteners.





“That which can be asserted without evidence can be dismissed without evidence”

Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^
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post #2 of 17 Old 10-09-2013, 03:50 PM Thread Starter
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Now tracing the bottom holes to cover up to catch fluids in case of a spill





As before, apply heat to form to the curves


Lay down adhesive. (JB weld)


Apply weight/pressure let cure


Fill in bottom cavities to make smooth

Do this a few times with sanding and reapplying to make sure you get all the
air pockets. This is Bondo Body filler with Red hardener, just like with the
nose plastic


Starting to wonder if JB weld will sponsor my track bike...
Mending the rest of the bottom together





Dzus fasteners came in


Creating the tabs for the Dzus fasteners. I scored the epoxy side with a
razor and drilled holes in it for extra grip on the epoxy.





Cut out a "V" to complete the last part that would catch fluids



Bottom fairing turned out real smooth. Filling in the center line with
filler then it should be good.





Since it is now October. . .



“That which can be asserted without evidence can be dismissed without evidence”

Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^
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post #3 of 17 Old 10-09-2013, 03:50 PM Thread Starter
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“That which can be asserted without evidence can be dismissed without evidence”

Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^
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post #4 of 17 Old 10-09-2013, 04:03 PM
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Looks good. I did the same thing but I just used fiberglasse to cover front cowl holes.

It's pretty easy to change for the track on my 05, basically remove the mirrors then remove the 4 screws where the lights attach to the front of the bike and the whole front cowl with the head light housing comes off.

What mine looks like.

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post #5 of 17 Old 10-09-2013, 05:09 PM Thread Starter
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Quote:
Originally Posted by Hitman123 View Post
Looks good. I did the same thing but I just used fiberglasse to cover front cowl holes.

It's pretty easy to change for the track on my 05, basically remove the mirrors then remove the 4 screws where the lights attach to the front of the bike and the whole front cowl with the head light housing comes off.

What mine looks like.

Thanks!


“That which can be asserted without evidence can be dismissed without evidence”

Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^
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post #6 of 17 Old 10-09-2013, 07:10 PM
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AHHH, yes, wee-hoppa, you have come very far!
I was at your house couple days ago playing with the bb, the track plastics really look good!
Did you find the orange quick-ties I left for you?

BTW, you stole my line: "I have more time than money"
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post #7 of 17 Old 10-10-2013, 02:58 AM
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good fucking job holy shit

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post #8 of 17 Old 10-10-2013, 03:14 AM
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I'm impressed for an Allatoona man ;-) Good job!

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post #9 of 17 Old 10-10-2013, 04:34 AM
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Nice work dude! You really got this fairing stuff down to a science. I think we should all start referring to you as the locak OEM fairing guru.

Track Bike: 2006 ZX6R
Daily: 2007 Speed Triple

A link to my build thread!
http://zx6r.com/racing/54737-my-2006...ack-build.html
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post #10 of 17 Old 10-10-2013, 05:16 AM
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Quote:
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Nice work dude! You really got this fairing stuff down to a science. I think we should all start referring to you as the locak OEM fairing guru.
he had a good mentor
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post #11 of 17 Old 10-10-2013, 05:36 AM Thread Starter
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Some better pics in outside light







“That which can be asserted without evidence can be dismissed without evidence”

Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^
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post #12 of 17 Old 10-10-2013, 07:55 AM
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Holy shit that is a lot of work. I'd be interested to see how this compares to fiberglass race bodywork in a crash.

If you want to really get all race bike on us, drill out two holes in the belly pan and put a rubber stop in. It'll make draining a lot easier after rain or blowing up a motor.
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post #13 of 17 Old 10-10-2013, 08:55 AM Thread Starter
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Quote:
Originally Posted by oKayH View Post
Holy shit that is a lot of work. I'd be interested to see how this compares to fiberglass race bodywork in a crash.
I've low sided the right side of my regular orange plastics twice theyre fine. but yes, OEM is harder so it handles sliding better. BUT, it is not as "squishy" or "flexy" like fiberglass is so it smashed and cracks a little easier. Time will tell. hopefully not on this bike. She is pulling double duty for now until i save up for a track only B model in the early spring

Quote:
Originally Posted by oKayH View Post
If you want to really get all race bike on us, drill out two holes in the belly pan and put a rubber stop in. It'll make draining a lot easier after rain or blowing up a motor.
noted...will add these before Barber next weekend. good thinking


“That which can be asserted without evidence can be dismissed without evidence”

Quote:
Originally Posted by pucksdown View Post
Drums had absolute control at full lean!
Fairing Repair--Condensed version
04 to 05 Swingarm Swap

For Motorcycle and Trackday videos, check out my youtube Channel
^^^ Look....Links ^^^

Last edited by mr5drums; 10-10-2013 at 10:39 AM.
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post #14 of 17 Old 10-10-2013, 09:52 AM
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he has a great sensei ....
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post #15 of 17 Old 10-10-2013, 10:11 AM
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I hope you know this is really helpful man! Thanks. :

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