Trail 90 air box repair

Jerhuntr

Jerhuntr

New Member
Anybody tried repairing broken air box plastic. Snout at the outlet to carb is broken off. It looked like it had plumbers putty holding it together. Been that way with a rock hard rubber for decades. Finally got a new rubber boot, just to find the broken snout. I finally see aftermarket available on ebay. Id like to keep mine, it has an original dealership sticker from Oakland Honda that is so cool I would hate to see it go. Trying J B Weld now. Once it's bolted up, it might be OK, but if it separates while riding...dust. saw a video of acetone and ABS plastic rebuilding a mounting tab, but I need the whole oval snout. If this fails, I might try to adapt a different snout (dont know what will fit yet) using rtv/glue and rivets
 
This is what I've done. So far, seems good. Did wax the insert but im not going to try to remove it. Waxed the boot for a mold for the last layer, perfect fit. I think once it's mounted on the bike it will be fine
 

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I have had success with ABS cement and drywall mesh tape on my Harley ABS tourpak.
The air box on my CT90 was already repaired at some point and the bolt flange was missing so I just bought a new one from EBAY.
 
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