Hello y'all! Well, as I wrote in my intro, I'm modding my rear end. Filled the fender after pulling the stock taillight and license plate. Took it to a pro for the final contour work and paint, and just picked it up Friday. Smoooooooth.
If you're thinking of this yourself, try what I did as it's easier than breaking it down in pieces from the bike:
PHASE I -
1. remove your extraneous stuff (sissy bar, luggage rack, etc)
2. remove the rear pillion seat
3. remove the rider's seat
4. disconnect the wiring harness
5. push the wiring connector and
the rubber grommet through the hole in the fender
6. place a box under the rear lip of the fender for support (or have your pal put his beer down and stand-by to help!)
7. remove the external (chrome) fender braces by removing 6 bolts (there's 3 forward near the battery box, per side, which secures the fender assembly to the frame
8. lift the fender up. CAUTION! It's tail heavy
From here on you've got easy access to the nuts which hold the taillight to the fender. But first! pop the wire run off the inner fender support. It's secured with nylon fairleads, and you can work them out carefully without breaking them. Now, take the nuts off and remove the taillight and license plate bracket.
9. remove the left and right fender braces. All you have left is the fender proper and the 5 rubber grommets and 4 steel washer. Remove the grommets and washers.
The fender's now stripped for the fun part!! There ought to be 7 nice big holes for you to fill.
PHASE II -
1. have a beer
PHASE III -
1. purchase (or scrounge) some of that nylon drywall repair tape ( the kind with an adhesive back)
2. purchase a 16oz can of ABS cement (medium, black). I used Oatey #30892
WARNING! ABS cement is very flammable and smells like "shite" (as y'all like to say!), so a place with good ventilation and a respirator might do ya
3. turn your fender "turtle" and clean the area thoroughly around the holes you want to fill; then rough the area with 250 grit sandpaper or Emory cloth. Wipe down with rubbing alcohol
4. cut pieces of the drywall tape and cover the holes
5. brush on a coating of ABS cement to your liking. Allow 12 hours to cure to hardness
PHASE IV -
Find yourself a way to stay busy until tomorrow
PHASE V -
1. turn the fender back upright and work-in the ABS cement into the holes. NOTE: This stuff suffers from some shrinkage, so it's gonna take more than one go 'round. Allow the whole mess to cure to hardness
Next is all up to you. Being a former aviation metalsmith, I went ahead and smoothed the fender myself as best I could in my kitchen. And, THAT saved me a LOT of money. But I let the pros take it when I got tired. I'm really happy with the results! It makes a major change to the bike's appearance.
Now I'm deciding if a side mount plate/light or a smaller Harley-style "BeeHive" light and a lay-down plate would be better. When I'm done I'll send a pic! Buck, out