Repair Plastic Parts

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Ever buy a sweet moped with broken plastic body parts and find out that gold is easier to replace?

Broken Side.jpg

Here's a tutorial on how to repair them, at least functionally. I'm not a pro enough to repair it to original condition, but this way should get your parts to be functional and durable.

Nearly everything I have is of Vespa origin, so those are the parts I'll use in this tutorial. For now, I'm fixing the floorboards from four Bravos. Later I hope to add pics of the side covers I need to repair.


Here's everything that needs some help. Vespa Plastic Parts.jpg


I use five-minute, two-part epoxy.

Epoxy.jpg

I also use fiberglass made for body work. Got mine at Wal-Mart. You can cut it with regular scissors.

Fiberglass.jpg

Step 1: Clean it up. Get all the grease and grime off. I used some brake parts cleaner to make sure, then let it dry.

Step 2: Grab a chunk of sandpaper. Grit shouldn't matter much, you're just trying to scuff the surface to make it rough so the epoxy will stick.

Sandaper.jpg

Sanding.jpg

Step 3: Follow the directions of the epoxy and mix some up. I mix it on an index card. For an applicator, I use strips of formica. You can get free samples at Home Depot, and then cut it into strips. Formica (you know, the stuff that is on your countertops) is more flexible than a popsicle stick. Anyway, smear some of it on the area you want to repair. Get some in the crack, but cover a good portion on the surface on both sides.

Smear Epoxy.jpg

Step 4: Cut some pieces of your fiberglass cloth and stick it on. Use your applicator (piece of formica or popsicle stick) to push the cloth down into the glue. You want the glue to saturate the cloth.

Fiberglass cracks.jpg

You can see in this picture that the top patch has the glue more saturated than the other two. If you need to, you can smear some epoxy over the top of the patch to help saturate it.

Fiberglass hole.jpg

The edges of the cloth can be a pain due to fraying, and sticky fingers from the epoxy. Just get it stuck down the best you can and let it cure. If you need to, you can add more epoxy after it cures to fill in dry spots, stick down edges, etc.

Here's one that is all done and cured.

Side Cover Repair.jpg

Well, that's the basics of it. Hope it helps. Hope to add more pics later. Ike Pipe

Added: Here's a new trick for me. Use some JB Weld SteelStik as a hole filler! I covered the hole from underneath using the fiberglass. I glued the edges of the patch, but left the middle for the Steelstik to stick to. I added epoxy after the Steelstik cured.

Footboard hole.jpg

Steelstik.jpg