My 1983 ATC110 Build

**kb0nly** · 06-12-2012, 12:12 PM

Awesome! I have a friend that has a plastic welder, i want one some day. I used his to put back together the plastics on an old beater quad we used to use out on the farm for fencing, snagged stuff in the pasture too many times and ripped off a rear fender. The only thing i can say about plastic welding, after doing it about a dozen times now, get the surfaces CLEAN. If there is and old glue or gunk on there it just won't bond right. Its like any welding process, start with clean surfaces to work with. With plastic welding though you can't chip off the slag and move on.. LOL Get some gunk melted in and you get a void in the plastic that will crack and fail in a short time. Otherwise its not too hard to do! If you hunt around enough you can get the color plastic your repairing in some new rods to weld with. We did a blue Kawa fender with some blue rods and built it up a bit above the surface, used various grits of sandpaper to block it down then a couple hours of buffing and polishing with compounds and you could hardly see it, looked like a small wrinkle line in the plastic from when it was originally molded is all, the back side we just left proud of the surface.

Looking great can't wait to see how yours turns out. Oh and if you got 6m plans for Field Day listen for me! I will be operating out of EN14 in South Dakota with a 4el Yagi on 6m and 500w, i will also be on 2m SSB with an 8el and 160w. I am the weak signal guy in the local club, love it!

**KI4UJO** · 06-13-2012, 12:12 AM

I'll look for you on Field Day. A buddy of mine, KJ4YXY, who is also 15, is coming down from Louisville to run with me. He got his general at Dayton this year, and hasn't actually run HF yet, so this should be good. Myself, I'll be manning the 857d and Ham Radio Deluxe for the PSK31 portion of our station. As far as I know, we will be running portable, being powered from a custom electric lawnmower I built, with either a G5RV laying in the garage, or some other wire that I come up with. If you're intrested in the plastic welder, it was $15 at harbor freight. If mine wasn't so badly cracked, I would have tried red rods and buffing. However, that's out of the question. Anyway, here's where I started today

Now, with the magic of time lapsing...

It's not the prettiest repair, but it's just as strong as the original plastic.

As you can see, it needs more work.

So, I stared with a 3M 60 grit disc and knocked down the weld on the top, and then applied the filler.

Filler

1st layer applied

And the sanding begins

As usual, I don't have more photos, but I got a lot more done. I may actually have this painted tomorrow, or at least primered and blocked. Here's where the bad part comes in for everyone here: I'm going out of town again, on Thursday. This time, I'll be gone from this Thursday to this Friday. Even if I was here, not much would get done. since after I spray this, I'm basically just waiting on the machine shop to tell me what piston to order. When I do that, I'll be ordering all of the motor parts that I need, so that I can get it back together. Once I have all of them, I can reassemble it, and get it going again. So, 73 for now.

**malibulvr** · 06-13-2012, 02:38 AM

Looking good, can't wait to see the progress on that fender. I have some similar problems with my 200M fender, may have to take a trip to HB for that kit. Keep up the good work.

**kb0nly** · 06-13-2012, 08:23 AM

$15 is a steal... I might have to get me one of those! I can see your crack is a lot worse then the ones we have fixed and buffed in those pics now. Will be watching how this turns out! Will look for you on the bands during Field Day!

**KI4UJO** · 06-13-2012, 11:50 PM

I'm tired and don't want to do a full update, but I'll squeeze it in tomorrow morning. However, you guys get this

**KI4UJO** · 06-18-2012, 10:13 AM

It's still not a full update, but I found time to make this one. Anyway, you saw that I got the fender sprayed, so here it is on the trike.

As for today's "progress", I called my machine shop and my cylinder is getting bored today, and I'll post a list tonight when I order all of the motor goodies. If I can find one for cheap (under $100, this and my e30 project are starting to get expensive) , I may get a performance exhaust for it. Otherwise, I'll be getting a hole in the other one welded up. Lastly, I'll be back in Mount Juliet on Friday, but Field Day is Saturday and Sunday (Eventually, I'll have to miss and go to TF) So, that's it for now.

**kb0nly** · 06-18-2012, 10:18 AM

Those fenders look nice!! Good job.

Can't wait for field day here either, itching to get going.

**KI4UJO** · 06-18-2012, 10:27 AM

I know what you mean. Hopefully, my station will be up and running on friday night, that way I can get any issues that I have worked out (Probably going to have problems w/HRD). Only 5 more days!

**KI4UJO** · 06-18-2012, 10:35 PM

Ok, well my machinist never called back (I'm willing to bet he called my home number), but I did order the decals today. I did an extensive search, but I didn't find any 1983 ATC110 decals that were available. I thought that I would use the 84 decals, but when pricing them out, it was stupid to pay $74 for the wrong set. So, I went to motodecals and bought a set styled identically to the ones on Tulsamike3434's 83, but in Blue instead of white. At $15, it saves me a good amount of money, and it goes with the Fake Anodized Gold wheels. It should look relatively good on it.

**KI4UJO** · 06-19-2012, 10:23 PM

Today, my machinist called back, and my cylinder is now ready to go. So, I ordered a .20 oversized piston from dratv, along with a complete gasket set. Also, I picked up the model year decal from atcheaven. So, I should have this thing running next week if I can get all of the parts in.

**kb0nly** · 06-20-2012, 12:47 AM

Woohoo! Will be fun to see the finished product!

**74sickness** · 06-21-2012, 04:38 PM

I got a 3 inch hole in my fender and im wondering if the epoxy will be good to fix it with and what did you use to paint it with btw nice bikee

**KI4UJO** · 06-21-2012, 05:53 PM

With a 3 inch hole, get some plastic welding rods and the welder, and go to work. You need to gradually build it up onto itself to fill the hole. After that, you can either leave excess material and sand that, or fill. I shot it in Omni AE, a single stage enamel.

**74sickness** · 06-21-2012, 06:42 PM

Great thanks a lot.

**malibulvr** · 06-22-2012, 12:53 AM

Do you have any trouble with the paint adhering to the fender? Did you just scuff the whole thing with scotch bright or? Did you have to use any special flex additive or just thin/spray from the can?

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