Back to the side cover repair. After multiple steps, Phase 2 is complete. All repairs have been made. After stripping the cover of its "as received" condition, it had multiple issues in need of repair, most of which were hidden by all of the layers of various colored paint over the years. It was not the worst cover I've had to re-build, but not the best either.
An image of the typical issues after grinding out the bad areas.
The cracks and ground out areas were reinforced on the backside. The top corner was reinforced when it is constantly pushing on the frame tube when mounted. As a result, this spot typically develops a crack in the paint over time..
The oil tank filler cutout is a typical spot for breakage. It was also reinforced on the backside.
The chipped corner was reinforced on the backside, then filled in with flox for strength.
The missing leading edge was fiberglassed up and then built-up with a flox mixture for strength. A top layer of glass was added to avoid any possibility that a crack could develop.
The cover is now ready for primer and paint.