Motorcycle lexan visor ****** repair questions.

[TT_Vert]

I have a BILT helmet (Made for cycle gear here in Illinois) that is about 3 years old. The visor is no longer obtainable (New or used) and this helmet has sentimental value to me and I'd like to continue using it. One of the lexan ******* that rides in a detent to hold the visor up has partially broken. I have some material there so I was considering finding a polycarbonate (lexan) epoxy to build up the ****** and sand it to size. I was also considering 3D printing a mold and not having to do that at all. I was wondering what you guys do to repair lexan/polycarbonate?

I am attaching a pic of the damaged side. Despite the appearance in this pic, there is enough base material that I will be able to bond to if I find a well adhering epoxy. I don't have any spare lexan to solvent weld this but any info to that effect is also helpful. Failing all this I could 3D print a new ******, drill and countersink for a small stainless screw into it but that would be my last resort.



Thanks much,

Dave

 

[gorilla]

Do you have a Tap Plastics in your area? They have a solvent cement that works for Lexan and may have small bits of Lexan avalable.

 

[TT_Vert]

Seems they are so on the West Coast and I'm in the Midwest so nope.

 

[Bigblue&Goldie]

How much is a used helmet (if you can find one)? The Bilt stuff isn't very expensive new relative to other brands, so maybe this would be a good avenue.

 

[Gutman]

TAP Plastic will ship the solvent and their prices are reasonable.
They've also got good guidance on a lot of plastics and how to fabricate stuff.
Check them out online or call them.

 

[TT_Vert]

I guess my question would be how to apply lexan to the ****** and fuse it. I was hoping to use the solvent to melt the lexan and put it on the ******/form. Then sand. But what I think i'd have to do is sand half the ****** flat and then fuse a piece to it then sand it round.

Dave

 

[whateg01]

...Tap Plastics in your area... have a solvent cement that works for Lexan and may have small bits of Lexan avalable.

TAP Plastic will ship the solvent and their prices are reasonable.
They've also got good guidance on a lot of plastics and how to fabricate stuff.
Check them out online or call them.

I guess my question would be how to apply lexan to the ****** and fuse it. I was hoping to use the solvent to melt the lexan and put it on the ******/form. Then sand. But what I think i'd have to do is sand half the ****** flat and then fuse a piece to it then sand it round.

Dave

I think a reasonable answer was already posted.

 

[cleaner]

Can you use the remaining material to create a boss with a flat top? You can then turn some PC rod stock to the required shape/dims and use 3M VHB adhesive for plastic to glue it to the boss that was faced on the visor. ideally you would be able to put a small hole in both sides and glue a metal rod in the center of each to reinforce it.

3M™ Scotch-Weld™ Low Odor Acrylic Adhesive DP8810NS​

 

[TT_Vert]

I would have to look closer, I think it sheared in half all the way down. If cannot create a boss I could just bring it down to the visor level and then bond a cut down piece of lexan rod of I can find one and profile as necessary.

 

[TT_Vert]

How much is a used helmet (if you can find one)? The Bilt stuff isn't very expensive new relative to other brands, so maybe this would be a good avenue.

It has sentimental value to me. It's not really about the money in this case.

 

[bdbecker]

It has sentimental value to me. It's not really about the money in this case.

I think @Bigblue&Goldie was suggesting to buy a used helmet to use as a parts donor for the one you want to keep/repair.

 

[TT_Vert]

I think @Bigblue&Goldie was suggesting to buy a used helmet to use as a parts donor for the one you want to keep/repair.

Ahh, i did look at that path as well. There are very few out there given this is made for a specific reseller (cycle gear). I have found a few used but they are asking $200 for these things and the visors aren't in perfect shape generally. If I could find a reasonable priced on in my size I'd buy it and keep for a spare and maybe but that hasn't happened. It has to be one of only two models: BILT Evolution Modular / Techno 2.0 Evolution Modular. I've been unable to find contact info for the manufacturer to see if either they have a reseller they could point me to or if another helmet brand they sell used the same visor. The helmet is about 3 years old now so i'm shocked i cannot even get a visor at this point. I'm going to do whatever it takes to continue to ride w/ this helmet though.

Thanks
Dave

 

[Bigblue&Goldie]

Yeah, I didn't word that right. I was thinking buy a used helmet to take the parts. I know for my helmet (Impact), the hardware and visor run right around $100. My first race helmet went obsolete and I couldn't get a visor for it, so I understand the issue at hand and it *****.

 

[TT_Vert]

Yeah, I didn't word that right. I was thinking buy a used helmet to take the parts. I know for my helmet (Impact), the hardware and visor run right around $100. My first race helmet went obsolete and I couldn't get a visor for it, so I understand the issue at hand and it *****.

The visors for this are $19-$22 so fairly cheap. I'm going to keep my eye out for a used helmet and at the same time probably buy some lexan dowel in a close OD and try to fix this one that way.

 

[Bigblue&Goldie]

I feel like my old Bell helmet had a brass insert in the visor that rode in the detents. I could be wrong, but that's what I recall. Also, my current helmet uses a screwed on stub/post for using tearoffs; a similar concept might work for you with your 3d printer.