Removing deep scratches from Buell plastic

[Bueller]

The process isn't complete.  I haven't quite finished, but its best that I tell you before you go trashing good parts. You can click on the pictures below to enlarge the images, or right-click on the link below them and Save As to get more detail.

For some reason we start with the fairing with the damage shown in the first picture. The Buell owners manual says that you can use Scratch and Swirl Remover to clean up scratches, but that deep scratches in black plastic are terminal. As you can see there was nothing to loose.

I used 800 grade wet and dry abrasive paper (used wet) and sanded out the gravel rash. There is one nick that is too deep to remove completely without reshaping the fairing,  I left this and it is barely visible.  I even sanded back the scratched lens in the headlight so I get away with it for now until I look at a brighter light option.

I chose one region initially as a test.  I sanded this smooth, and I was almost willing to believe that the handbook was right about the black plastic.  I hit this region with cutting compound, and it became smooth very quickly and showed a promising shine.  I removed the gravel rash from all over with the abrasive paper, and then cleaned it up with the cutting compound followed by Scratch and Swirl Remover.

My main mistake was not to sand again with a finer abrasive paper.  I left too much for the cutting compound, so it took longer than it should have.  I say it is not finished because I have a film on the fairing from the cutting compound that is difficult to remove, so I cannot be sure that I will get back the full deep gloss until I get rid of this.  I have a new fairing, but I will put it away. This one has come up fine for every day use. The damage doesn't show. I'll attempt the buckle scratch in the airbox cover next.

Sanding took about 15 minutes.  The rubbing with cutting compounds about two hours.  As I say it would have been easier if I had graduated the sanding.

It is not a fragile bike.

[Rogue]

Wow.  Judging by your pics, it came out pretty good.  Good job!  

[dgunther]

Nice work.

I'm glad that Buell uses Surlyn for the plastics.  Tough stuff and being colored all the way through it, it makes it easy to deal with little stuff that would require repainting on other bikes.

I use a tankbag on my Uly and it tends to rub scratches and swirls in the plastic, but they buff right out with a little 3M rubbing compound and it looks good as new.

[Kootenanny]

Looks good!  I'll keep this in mind--there are a few marks from my saddlebags (nothing but bugs on the fairing so far... ).