ENTER THE 1985 HONDA NS400R…(Part 3)
I’m going to attempt to catch you up on the latest progress on the Honda project, although I will likely miss many details. Where I left off on the story earlier was bodywork and I made a great leap forward in that area.
Considering the rarity of parts for this bike and my frugal ways (I’m not going to pay $400 for a small pristine plastic body panel as some are offering them for), choices were extremely limited. But my patience paid off again and I found some reasonably priced side body panels in Europe and had them shipped over (shipping was almost as much as the parts!).
The first part to arrive was in pretty good shape overall, but was in need of paint.

The opposite side panel, however, was nearly tossed out as junk. In the Ebay pictures, it looked fairly decent, but there were “conveniently” blurry pictures of the really bad sections of the part that I (as an optimist) assumed to be fine.

But when it arrived, it was in pieces, despite being packaged very well. Plus, the leading edge was warped, like it was involved in some sort of carb fire or something. The package was taped up really good, but despite searching three times, I could not find all the missing pieces. In this picture, you can really see the warped tip up by the fuel valve hole and also the missing area where the lower mount hole would normally be.

I sat on it a couple days and then I decided this might be the perfect opportunity to learn a new skill… PLASTIC WELDING!!! So I armed myself with a few inexpensive tools to give it a try.


A heat gun was used to reform the front flange back to original shape and things were looking up.

For the missing pieces, I traced out the profile on some spare ABS sheet and cut it out.

And then the filler piece was formed and tacked in place. Again, the situation and my success was looking even brighter.

I’m going to attempt to catch you up on the latest progress on the Honda project, although I will likely miss many details. Where I left off on the story earlier was bodywork and I made a great leap forward in that area.
Considering the rarity of parts for this bike and my frugal ways (I’m not going to pay $400 for a small pristine plastic body panel as some are offering them for), choices were extremely limited. But my patience paid off again and I found some reasonably priced side body panels in Europe and had them shipped over (shipping was almost as much as the parts!).
The first part to arrive was in pretty good shape overall, but was in need of paint.

The opposite side panel, however, was nearly tossed out as junk. In the Ebay pictures, it looked fairly decent, but there were “conveniently” blurry pictures of the really bad sections of the part that I (as an optimist) assumed to be fine.

But when it arrived, it was in pieces, despite being packaged very well. Plus, the leading edge was warped, like it was involved in some sort of carb fire or something. The package was taped up really good, but despite searching three times, I could not find all the missing pieces. In this picture, you can really see the warped tip up by the fuel valve hole and also the missing area where the lower mount hole would normally be.

I sat on it a couple days and then I decided this might be the perfect opportunity to learn a new skill… PLASTIC WELDING!!! So I armed myself with a few inexpensive tools to give it a try.


A heat gun was used to reform the front flange back to original shape and things were looking up.

For the missing pieces, I traced out the profile on some spare ABS sheet and cut it out.

And then the filler piece was formed and tacked in place. Again, the situation and my success was looking even brighter.

















































































