ZX-6R Shaved Passenger Handles Modification

Burner's Process for Shaved Handles:

• NEVER use bondo, use Dura-mix. Bondo will crack and/or
  split apart over time with excessive vibration.


• Dura-mix is a liquid plastic that comes in a special type of
  caulking gun. It's a two-solution mixture. Both solutions come
  out of the same hole in the tip. One part is the plastic while the other
  is the activator. When they are mixed together the activator
  begins hardening the plastic, allowing just enough time to apply.
  Dura-mix is a product that professional auto repairers use to
  repair plastic bumpers on cars.


• You will also need a "patch". The patch is a piece of woven wax paper
  material that goes behind the holes.


• Remove the handles.


• Next take an air grinder and "level off" the rear holes where
  the old handles bolted down.


• Sand the area where the Dura-mix will be applied
  (inside and out).
• Using rubber gloves, cut a piece of the "patch" material about 1"
  bigger then the holes.


• Apply a small bead (of Dura-mix) around the inside of the
  holes in the trunk area and stick the "patch" material on the bead
  to cover the hole.


• Once that is dry, finish filling in the holes on the outside
  of the tail section with the Dura-mix.


• When the Dura-mix is completely dry, sand it to the contour
  of the tail section until it has a nice smooth finish.


• Prepare the tail section for painting.


• The final step prior to reinstalling your tail section is to
  cut the area where the rear of the handles bolt to the frame.
  "I was worried to death about cutting them, because I thought it would
  make the tail section unstable, but it didn't. I ride with my wife on the
  back all of the time and have not had any problems." - Burner