996. From Ratty And Tatty To Pretty Natty

@West Cork Paul
Just been thinking about this. I had not intended to run this thread as it’s just a tart up job with an interesting back story. But. We are all bored.
The hugger is a problem but it’s a genuine MS Production part and I think I will have a good go at sorting it. Before your post I was resigned to just chucking it on as it is - it’s not meant to be an immaculate bike after all. It’s going to take a fair bit of work and more importantly, time. Delaying the final assembly. But, so what?
So, I will document what I have done so far and then step by step going forwards. I hope and think I can make it good. Promise to show pics as I go. We can all then learn.
Next episode. Hugger repair.

 

Might do but it’s passable on the fairings at mo. End pics will tell the tale. Got a few plastic bits that I can tart up as I quite enjoy the process (wife doesn’t but there you go!).

 

To continue.

The headlights were not as I would have liked them although someone had previously cleaned the insides they had not done a great job. So, lights off and Mr Muscle. Also a spot of cleaning and polishing, not to a mirror shine but clean.



Next up was the carbon effect stickers that had been stuck on the fairings. I was a biot worried about what I would find underneath, but it was all ok:



The bodywork could really do with a respray if it was to be returned to mint, but its OK-ish and pretty good for 25,000 miles. Sticker board hid a few stone chips. 996 stickers on the BIP unit I sourced courtesy of The Image Works for £5 both sides.:



So, apart from the carbon, we are on the final straight.

 

Next, just for Paul, the carbon fibre.

All the CF was removed. Flatted back with soapy water and 400/800/1200 wet and dry. Cleaned thoroughly with acetone. Then sprayed in a room with a temperature of c23 degrees. The tank pad, heat shield and clutch cover got about 5 coats of Halfords Bodyshop Professional Lacquer. The hugger got 7 coats initially, followed by a further 7 when I saw the results. After that I went over each hole individually with two further coats of lacquer applied with the tip of a modeling brush. This made no discernable difference. It was (is!) in poor shape.

Here it is after 14 coats plus 2 pinprick attacks (this part of the chain guard looks nice TBH):



Looks okish until you take a close look:



In places the weave was so thin you could actually see light through it and it was this general condition that has caused the fisheyes or pinpricks.



Normally I would just flat down and then polish, but to attempt to deal with these pinpricks, drastic action is necessary (It may or may not work).

Flat down using 1200 on a sanding block.

When flatting down, take it easy, use plenty of soapy water. the lacquer comes away as a cloudy film:



After flatting down, the pinpricks and any low spots clearly show as they are still glossy:



The next stage is one that I have used once before on the 748 swing arm protector with pretty good results. The pinpricks are small holes that need to be filled then flatted off. CF is a weave impregnated with resin, normally under pressure. I apply a dot of Araldite Crystal to each pinprick using the tip of a cocktail stick. Araldite Crystal is like the normal stuff but dries clear. There may be other or better things to use but that's what I have used.
Boring and tedious work. This is the current situation with hopefully most if not all the imperfections covered in the resin.



It took me several hours to do all of this.

Next step is to let it dry thoroughly even though the resin is only workable for 5 minutes. This will take a few days. Then its back to flatting etc. I will of course document the progress, I only hope it works as there are a hell of a lot of imperfections on this. Nothing ventured

 

Good question. I removed the tank pad and the tank is in good shape underneath. But, I lacquered up the one off the 748 as its in better nick than the one on this 996. Undecided if I put it back on or not. Currently thinking that I will as it has a carbon key protector that looks good and this matches up.

 

Nope, just for show. They were on the top of the fairing as it adjoins the airbox.

 

Thats what I thought until Paul stuck his nose in

If I had your swinging arm I would leave it off as well!!

 

Ok.

Ok.

I converted the shower cubicle in family bathroom into a nice spray booth. The smell went after a few days.

 

Right.
The hugger has been on a window sill above a radiator until this afternoon.

Fingernail said the blobs of resin were cured.

Wet and dry with soapy water, started with 1200. Not abrasive enough. 800 was much better, needed 400 on some bits. So, taking my time, 400/800/1200/2000/2500 grit with soapy water. Took a good couple of hours, bare hands, feeling for high spots as I went.

End result looks better and I am hopeful of a reasonably half decent finish. That will be done with a dual action buffer using Maguires compound, polish and finishing with wax. I will try and do this tomorrow.

Here's the obligatory shot of today's efforts:

 

Well mate. I forgot it was the Mrs turn to cook tea (toad in the hole, mash and beans - yum).

So, out with the polisher.

Pretty happy with the results. Not perfect, but a damn sight better than it was. Thanks @West Cork Paul

 

Good man. Patience and prep are key.