DIY Track fairings from OEM plastics

This is from my thread over at ZX6R.com. I turned a cheap set of OEM into "track compliant."
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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 :coocoo.

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. 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.

 

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. . .

 

Some better pics in outside light

 

thank you sir.

I get to put them to use next weekend at Barber. riding saturday N group.:getdown:

 

yep! fits perfect just like OEM.

Thanks Hen! you gonna be at Barber with me and David?

 

This actually took me a few weeks. I have quite a busy schedule with my regular 9-6 job, a second job 2-3 nights a week until 9, and a wife and 11mo baby girl. So I have been doing this slowly...about 4-5 hours a week spread out. :thumb: :cheers:

BRAAAPP BRRRAAAAAAP!!!!!! :wheel:

 

yeah he'll be there friday afternoon setting up. I'll get there friday night about 10 so i might have to sneak past the gate somehow