How to Make Fiberglass Fairings

Motorcycle fairings aid in the aerodynamics of sport and race bikes. They wrap around the front of the motorcycle, sometimes encasing the legs and body of the rider. Because of the nature of the sport, race fairings are frequently broken or damaged during competition. A damaged fairing can be replaced by reproducing the form in fiberglass. This fiberglass fairing can then be painted to match the rest of the bike using automotive enamel paint.

Things You'll Need

  • Original fairing
  • Mold release spray
  • 36 square feet of 1 1/2-oz. chopped strand mat
  • 1 gal. resin
  • Paint brush
  • Flat aluminum roller
  • 220 grit sandpaper
  • Automotive acrylic primer
  • Automotive acrylic enamel paint
  • Automotive acrylic clear coat
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Instructions

    • 1

      Shake the spray can of mold release spray for 30 seconds. Spray a light coat onto the front of the original fairing. Allow to dry for several minutes. Spray a slightly heavier coat and allow to dry. Apply two thick coats, allowing to dry between each coat.

    • 2

      Overlap the edges of chopped strand mat strips, arranging a single layer on the front of the fairing.

    • 3

      Brush a heavy coating of resin onto the strips and push all the air from under them with a flat, aluminum roller.

    • 4

      Add another layer of chopped strand strips and another coat of resin. Repeat until at least four layers have been applied.

    • 5

      Allow the fiberglass to cure until firm. Check drying times on the resin packaging for estimates, because different compounds dry at different speeds.

    • 6

      Separate the new fiberglass form from the original fairing. Sand until smooth with fine grit sandpaper.

    • 7

      Brush on one coat of automotive primer. Allow to dry for four to six hours. Spray one coat of automotive paint onto the fairing, followed by four to six coats of automotive clear coat. The fairing will be dry to the touch in two to four hours and can be mounted to the bike after 12 hours.