Bodywork FAQ

compiled & edited by Kristian #562
Please read the Disclaimer before attempting any work in this FAQ.

For Painting the Acerbis Tank see Aftermarket Fuel Tank FAQ Classic

Paintwork Touch-ups


Flash #412
December ‘01


“Scuffed the paint off the luggage mounts, crash bar and hand-grip end. So the question now becomes what is the best choice for touching those areas up? Is this a standard glossy black automotive paint on these parts or is it some sort of magic goo available only from Dieter and the boys in Bavaria?”


Minor Touch-ups


Get a tiny bottle of Testor's Model Paint, black gloss. Tough as nails. Just for one minute touch ups. No sanding required, even.


Painting Black Gloss


  1. For SERIOUS black gloss painting buy Engine enamel in a spray can.

  2. Sand the parts to remove the gouges, if you care.

  3. Finish sand the parts with 400 to give some "teeth" for the new paint.

  4. Spray with engine enamel.

  5. Give it a VERY light "tack" coating.

  6. Wait about three minutes for it to tack up.

  7. Then, give it a single good coat of paint, just so it looks evenly "wet."

  8. Let dry at least over night.

  9. Put your oven rack in the TOP position in your oven when your wife is no where about.

  10. Suspend the parts by their mounting holes with paper clips or bent pieces of coat hanger. Bake the parts like brownies. ~325 for ~20 minutes.

  11. Let cool.

  12. Mount. (The smell won't last very long in the kitchen. It won't linger in the oven at all. Take her out to dinner.)

The guy who showed me this was SERIOUSLY into Vincents. That is how he did all the parts on his Black Shadow that would fit in his oven. And his Rapide, and his Egli. (His Comet was burgundy, so no black.)


I suggest using Testor's on stuff like scraped bar ends, control lever knobs and such. I did not suggest using a brush paint on a big surface like a gas tank. That should probably be sprayed. Although, some Testor's and some sanding could probably fill in some nasty gouges. But you'd still need to spray something over it, or else spend WAY too much time sanding and rubbing.


More Scratch Repair Advice:


Not another Scratch!



Gluing Plastic

Gluing General:

Get some Super-Glue (or equiv) and some baking soda. Put glue in the joint and then make a nice fillet of glue around the crack on the outside. Sprinkle baking soda on the glue. Let dry for an hour or three and see if that don't get it.
Flash #412

Gluing Fender

Problem: Glue recommendation to fix front Dakar fender I need to know what type of glue would work well on the back BMW fender plastic. I've got a crack in the black plastic part of the front fender and I'd like to try some glue before buying a replacement. The crack is only about 2 inches long. Chicago, '01 Dakar


First thing you should do is drill a tiny hole at the end of the crack so it does not spread any further. I believe the plastics on out bikes is ABS or Acrylontrile Butadiene Styrene. If this is the case Methelyene Chloride acrylic cement should work well. It is a watery substance that melts the plastic and then as it dries fuses it back together, it works very quickly. I have a jar of it sitting on my desk for a similar repair. I have not had a chance to try it. I will let you know how it works out. It is hard to find, I ended up phoning in an order to Michigan and with shipping it was $8.75 and came pretty quick. For more info on fixing plastic check out MasterITRIT


Gluing Driving Light Support Bracket

I'm adding driving lights and will be mount them to the plastic fairing just above the turn signal lights. I want to reinforce this area (maybe 2 inches by 4 inches) by gluing another thin layer (1/16 or so) of plastic to the back side. Does anyone know what plastic I should use and what glue? My plan is to try mount the lights using brackets I made and using the same rubber nut/screw thingy’s holding the wind screen on. I'm thinking that if I take a fall these may pull through instead of breaking the fairing. I will see how these seem to mount the brackets. If my bike didn't already have damage to the fairing from the previous owners fall I would be thinking twice about drilling holes in it. The thought of using polyester resins to reinforce would work but I need to keep it thin to use these thingy's. I'll put a thin piece of metal back there and use some epoxy then the fender washers.

Painting Plastic
A Change of Color
Sean #807

EZ - You don't need experts. I painted mine for about $80, including reflective tape.

  1. You need to remove all the decals. A hair dryer is used by a lot of people. I boiled some water and ran it over the decals, extra water at the corners. Once started they lifted right off. Had a cuppa too.
  2. Wet Sand the entire surface to be painted with #600. Do a really thorough job. Clean when finished.
  3. Go to Pep Boys. get some stuff in Aerosol cans labeled "Adhesion promoter". This is critical. Apply two light but thorough coats. Do not sand!
  4. While at Pep Boys, grab some flexible primer. Again, two light but thorough coats. Wet the final coat with #600. Go easy bond the sanding.
  5. Color. Well, here is the Devil in the Details. If you go the lacquer route, and want to spend a lot of time sanding between coats, and finish everything with clear-coat and lots more sanding (#100, #1500, #2000) be my guest. But for day-to-day stuff, just go with Enamel. Apply 2-3 light coats, and it will look fine. I went with "bumper paint" which has a little more flexibility.
  6. Enjoy the results. Leave the $$$$ paint jobs for wankers. Cheers.


Painting the Engine

New Panels

Removing Stickers

Q. Anyone knows how to take stickers off of my Bike, it's those 'Check the Oil Regularly' and 'Use only Unleaded Fuel' type of stickers.
A. Heat em up with a blow dryer and try pealing them off. Mark #403