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Old December 24th, 2018, 11:57 AM   #1
Guaire
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Broken Tab Repair

Working on my new to me 2004 Ninja 250. I attached the two broken tabs with Oatey ABS cement. For structural strength I added Sugru to brace the tabs.

https://www.youtube.com/watch?v=RoTlG1D-T58
Attached Images
File Type: jpg Tab R Otey z.jpg (211.1 KB, 4 views)
File Type: jpg Tab Right z.jpg (235.1 KB, 3 views)
File Type: jpg Tab Sugru R z.jpg (247.0 KB, 3 views)
File Type: jpg Tab R upper z.jpg (182.2 KB, 3 views)
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Old December 24th, 2018, 07:46 PM   #2
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Awesome work! That sucka's not going anywhere!!!
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Old December 25th, 2018, 03:46 AM   #3
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Interesting. I wouldn't have thought Sugru would offer any structural strength.

I did a similar repair on my GSXR fairings using some plastic-repair-specific epoxy. Don't recall the exact product... it's down in the shop... but it worked well. Like you, I felt it wise to built up the area around the peg/tab to spread out the load.
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Old December 25th, 2018, 08:19 AM   #4
Guaire
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I just handled the tabs to see how they are fixed. Sugru takes 24 hours.
The glue I used is ABS. It will actually bind to the back of the ABS side cover. The glued joint has no flexibility though. Not being able to bend, means it will break under stress. Motorcycles live in a world of constant vibration and sometimes shocks. With the Sugru cured, there is structural strength due to its mass. Yet, the Sugru as it is cured rubber has some flexibility. That flexing transfers vibes and shocks through the mass of rubber. I believe that will hold the tabs better than hardened ABS. Rigid ABS will transfer vibe energy, not dissipate it. ABS sticks the parts together and Sugru holds the tab up and transfers stresses into the giant panel cover.
Whenever you deal with structural stresses you have to create a path for the stress to run through and out of your build. When designing saddlebags for heavy loading, you have to place every part where it will bear the load, not letting the stresses beat anything apart.
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Old December 25th, 2018, 08:19 PM   #5
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I usually reinforce base with filet of fibreglass. Spreads out stresses to wider area away from base.
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Old December 26th, 2018, 05:25 AM   #6
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nice, good job
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