Few months ago I brought the undertray which you see fitted in the above photo (the photo doesn't do it justice). It's made for the Bandit 600 so needed to do some cutting and filing to get it to fit, I've left the pillion grab bars in place as I didn't what to cut them off at this moment in time. There are areas where the undertray doesn't meet the b4 bodywork very well if not at all, also where the battery meets the undertray the tray will need cutting-out and reshaping so the battery can be refitted. As well as this am reshaping the rear of the undertray where it also meets the rear light and the two fixing bolts for the rear b4 bodywork. To do this' I need to fabricate number of backer plats which allows you to lay-up the repair the same way the undertray was built--gelcoat first. Which hopefully will means very little finish work will be required.
I google' moulding material's but couldn't find anything that would make my life any easier so decided to return back to the old trusted car body filler to fabricate the backers. The photos below shows some of the backer plates I've made-up so far, these still need some finishing off, i.e. more reshaping, smooth-out and painting.
When I get to re-fibreglassing the undertray the backer plats are waxed with releasing compound and then fixed to the outside as tight as possible to the undertray which is first turn-up-side-down, then lay two coats of black gel coat into the repair areas, once the gel coat becomes tacky start to lay-up the fibreglass fabric mating, when the repairs are done let dry for 24! Hours and then removed and discarded the backer plates.
I've been working on the swingarm on and off over sometime now regards to polishing and possible other ideas which is why I haven't cut anything off yet? . The photo shows how the swingarm might look like but since this photo was taking it's been re-sander back again before being re-polishing again.I do have a set of extractors somewhere but can't find them so looks like I have to buy new set.
Again this happens a while ago' it pays sometimes to walk away from a problem but not this long.