Hi
I stripped down repainted and tidied up my 3AJ a couple of weeks ago. The pictures are of the old girl in her new livery. I took moulds off the plastics of the front guard, side panels and rear light cover and made replicas in fibreglass. I'm pleased with the results, they worked out well for me.
I've a fair few 3AJ bits and pieces kicking around in the workshop including a good tank which I don't need. Though I realize that unless someone in NZ is doing up a 3AJ shipping would be a pain but they're here if anyone is stuck for bits

Nice one.

You should have done a rebuild post & let us all watch.

Mezo.

PS, i fixed up your pics for you.

Very nice job
Would be interested to know how you made the moulds and then the fiber glass replacements? Did you use a special release agent and gel coat ?
Re your 3aj tank, any dints? I know I am across the ditch but I am over there with work pretty often. Perhaps you could PM a picture and price?

Hi
Haven't had a chance to get back to this for a while due to domestic upheavals. I'm leaving NZ so all my bits & pieces are in a shipping container I bought. When I get settled again I'll go through all the XT600 Tenere stuff and post what's there.
Taking fiberglass moulds off the plastics is a doddle. Just check with a bit of acetone on the inside of a plastic that it doesn't affect it ( which it won't on front mudguard and side panels and any other moldings of the same plastic.
Clean it well and remove any transfers, scratches are not a problem as you can sand and buff your mould. Wax the plastic with mould release wax. Apply gel coat, then fiberglass tissue, then layers ofchopped strand mat until it's thick enough to hold it's shape. Use polyester resin for this it's cheap and nothing better is needed. Watch the MEKP hardener it causes nasty alkaline burns if you get it on your skin and don't wash it off and will cause real problems if you get it in your eyes !
Because the plastics are flexible you can get them out of your mould easily. If your'e uncertain that the plastic will release you can paint or spray on a coat of pva water soluble release agent after waxing and before your layup.
Tidy up your mould by filling, sanding and polishing ( you can paint it if necessary I use a durepox 2k grey). Mould release wax and pva then layup your item using vinyl ester resin, no gelcoat if you're going to paint, tissue then chopped strand mat again, use a fairly lightweight mat it's easier to roll, wet out and and shape. leave it to cure for at least a day before popping it out of the mould. fettle and paint that's it.
If you want a clear coat carbon fibre finish, clean off all the pva residue and sand to get a rough surface, drape 400 grm carbon cloth and wet out with SP115 epoxy resin, just stipple the resin or you'll spoil the weave. when it's gone off brush on another coat of 115, repeat if necessary to get an even coat,sand lightly (320 grit )and spray with an automotive 2 part clearcoat.
Do a bit of practice with some small parts to get your techniques right. Because of the small amounts involved it's cheap and rewarding.
I'm off to do some boatbuilding in Spain, I'm picking up a 900 Cagiva Elefant I've bought from a guy in England and riding to Spain ( hopefully without too much drama) When I get a home base again I'm going to do engine rebuilds on the twin headlight 3AJ and my 1Vj which I'm putting a 3AJ motor in.

All the best on the trip, i'll be waiting to watch the rebuild i reckon i'm going to have too do 3 rebuilds myself.

Lovely bit of polish on that. I didn't realise they scrubbed up so well. Mine looks like it's spent six months being thrashed around the desert, but then it has.

Im guessing you honed your skills boat building right? have you worked on any of the racing yachts? (Americas cup)

Mezo.

Yes Americas Cup and Volvo round the world contenders. We just painted the team New Zealand cat at 72 ft and a proposed 45 knots it looks bloody dangerous !
I just posted details of the carbon fibre tank protector that I've made for the 3AJ

Dawn! I surpose you have left NZ by now? Would have been very happy to buy some side covers off your moulds before you shipped out. Oh well too bad. Will have to have a go making my own out of light ali. I've got the Left hand as a "adapted" sample, which fits the Zega panniers ( if I ever manage to get the previous owner to put a price on them...) Will have to "have a go" Have fun in Spain.