99 Trunk Needs Major Repair

[FROG MAN]

Maybe I can get some pictures up later. I just removed the trunk to see how bad it was. I'm talking 6 inch cracks up the side,up the back,across the bottom almost end to end. We got one chunk of plastic missing about 2 1/2 inch square. Obviously this one did not get the Yamaha recall repair in 99. So for a cheap quick fix now ASAP what are my options. I don't care if I have to replace the trunk later but now time is the problem.

[thebighop]

I have some major cracking in my 1st Gen trunk and used a liquid plastic polymer that is used to repair Corvette bodies...I found it at a auto body supply outlet..it's a bit pricey, but worked better than anything I had tried before that...

[SaltyDawg]

What year and what color?

[PBJ]

also try a local boat shop that does fiberglass repair they should eb able to lay patchs from the inside that add polymer to fill any missing pieces . Your may not have to replace it after that. My 85 had fiberglass repair. Looks like a homemade job but its on the bottom and not readily visible. the trunks solid and waterproof.

[Yammer Dan]

I have rebuilt some smaller pieces with ABS glue. The fiberglass patches I've seen might be the way to go if you could layer it on the inside good.

[FROG MAN]

Here are the pictures.

 

[Yammer Dan]

Ouch!! I got some thoughts. Need to look at something to reinforce it like road sign, and cut piece to fit and pour fiberglass over it to bond with trunk floor?? Wouldn't do that again.

[Holly]

Mine is about that bad. Was going to get some scrap alum from work and bolt it to bottom, and seal it with silicone. Appears to have enough clearance on bottom to allow 1/8" thick piece to work.

[Freebird]

After seeing the demonstration that Plastex put on at the International Rally, I'm pretty much sold on it. I think that is what I would use.

[Yammer Dan]

How much Plastex to cover that thing 1/8 inch thick? And to work in cracks good to create good bond.

[Gold Rush]

http://smg.photobucket.com/albums/v208/01REDWING/th_mmtrunkfix002.jpg

 

I thought the crack in my '01 MM was the previous owner's fault. Now I'm seeing a trend.....

 

Just finished what I hope is permanent fix to my problem. I took pieces of 10 gage metal and fitted them individually into each of the little areas across the back/bottom of the trunk (inside and out) then pop riveted them together and laid a layer of fiberglass over the metal patch. Now if the repair will just hold. I had used plastic repair kit that I got off the INTERNET about six months ago and it held for a couple months. Time will tell....

 

I did a quick e-bay search and found a trunk up in Wisconsin for a 2000 MM Limited. I think the bid is around $130 now. This trunk would need to be painted to match your bike and it has small cracks around the mounting holes that would need reinforced. That's a really good price compared to the $500 a new trunk will cost. Here's the link... Hope you get the problem fixed.

 

http://cgi.ebay.com/ebaymotors/Yamaha-Royal-Star-Venture-XVZ1300-XVZ-1300-TRAVEL-TRUNK_W0QQcmdZViewItemQQ_trksidZp1638Q2em118Q2el1247QQcategoryZ84147QQihZ002QQitemZ120107981306QQrdZ1QQsspagenameZWD1V

Edited July 14, 2008 by Gold Rush
added photo

[waterbug]

If you are going to fix it go to a autobody refinish store in your area and tell them what you have and what your options are. doing bodywork for a living somethings will not stick or stay on abs plastics and some things will eat at them and make them soft. There are alot of good products out there but you have to match up what you need with what kind of plastic you have. If you are not going to fix it then check around to some good bodyshops I am sure they can take care of you and paint it too. Good luck I hope it works out for you

[kevin-vic-b.c.]

Ok I know very little about auto refinishing..... less about trunks...... BUT...... I am a plumber and I know ABS..... I know you can go to an industrial plastic shop and purchase 1/8th inch or 1/4 inch sheet ABS....... IF these trunks are actualy ABS then with a sheet of repair product in hand you can easily cut this to size and shape and go to a local plumbing suplier and purchase ABS cement that plumbers use to bond the drainage piping together..... this product will bond the repair part to the original ABS permenantly.... This is all a guess with the assumtion that the trunk is ABS as I know ABS.

 

Let me know if I should stick to plumbing.......

 

Kevin

[cmiles3]

I did a similar repair on my '87 trunk. I used fiberglass cloth & ABS cement. I patched it last year, and it's still solid- close to 10,000 miles on the patch. I have used Plastex to fill gaps with missing ABS; it works as advertised. Do the fiberglass patch first, then use Plastex to fill holes & gaps.

 

It took me a couple of evenings before it was ready to mount. I started by cleaning the plastic with thinner. After it dried, I applied ABS cement, then fiberglass. Wet the fiberglass with cement first. Then multiple coats of ABS cement, to fill the voids in the fiberglass. The cement sets up fast, so it helps to have the patches precut. Wear plastic gloves.

[VentureProf]

ABS, no doubt. A sheet of ABS with ABS plastic cement should do the trick. I fixed a broken tab (holding a captive nut) on the inside of my left lower faring with ABS cement and some ABS shavings from a piece of ABS pipe I had lying around. Worked perfectly - still holding strong.

 

Kelly

[FROG MAN]

OK going to try the fiberglass cloth with resisn mixture. I know a few ole boys that might do it for free just to get the inhale experience.:rotf::rotf:

 

More later.