Cracked trunk lid

[Eydugstr]

Working on a 90 xii, and one of the problems is the trunk lid. It has a cracked piece on the front right corner that seems to keep cracking despite three ABS cement fixes and shims placed inbetween the hinges. Is there something I'm overlooking? Are there any rubber bushings that wear out after a period of time that need to be replaced? The weatherstrip looks in good shape.

[triton28]

I have a complicated procedure which seems to work when I repair body items. I grind down the inner surface and the outer surface surrounding the crack/missing piece using a Dremel with carbide burrs. The extent to which I relieve the lateral area of the plastic depends upon the size/shape of the repair I want to make, but I always go at least 1" beyond the edge of the crack/missing area.
What's left is a portion of plastic in the middle of the the original thickness of the plastic which then gets sandwiched on both the inner AND outer surface between multiple layers of epoxy, NOT polyester, resin soaked fiberglass cloth and sometimes strand if it is a curved inside surface. Sort of like a tenon of a mortise and tenon woodworking joint being brought back to the original thickness of the board before the tenon was machined.
The area I had ground down provides sufficient depth for the cloth without being above the adjacent finished surface surrounding the area being repaired. Low is better than high, as sanding is a pain in the butt unless it is spot and glazing putty to get fair with the original surface. Then it's time for primer, more spot and glazing putty, primer etc. etc. and then base and clear coat.
It's a lot of work but I find it works for me.
Dave

[Eydugstr]

TY for the response - Hope it doesn't come to the point where I have to patch it with fiberglass or bondo...BTDT on sidecovers for other bikes before. Just wondered if there was something specific to these bikes to look for on the trunks.

[Mr Jensee]

You might want to check Ebay for someone selling off trunk lids or entire trunks. Usually these used parts are cheap.

http://www.ebay.com/itm/Kawasaki-Voyage ... KQ&vxp=mtr