So I got a 1989 CBR600F and it needs some repair to the panels that I did get with it.
However, it is missing the belly fairings including the little inspection panels that fit in it.
Thinking that I can't afford replacement second-hand OEM fairings, and most of what I have seen are not only eye-wateringly expensive, but come with their own damage.

Was thinking about 3D printing some replacements. I have done some 3D printing in the past but I have never printed in ABS or ASA (PLA/PETG completely unsuitable) so that will be a bit of an adventure. I hear that it can be a pig if you don't make the proper preparations. I have done my research and will give it a go.
The parts are going to have to be printed in sections with an added lip to each join edge to enable welding or bolting together, since they are way too big for me to print in one go. Also probably better to build from smaller pieces to avoid too much warping etc. and reprinting if one of the parts needs modification.

I think that the biggest challenge will be the 3D design of such an organically curvy part and get it to hug the bike in the proper way.

Does anyone know if anyone else has tried to go this route before? It is so obvious, I'm sure there are others out there that have tried this.

 

Good luck with that, I have not come across anyone that has tried it yet, but must be the way forward as OEM bits become way too expensive / unobtainable

 

@skelband Did you end up trying this? With 3d scanning and larger print services available and accessible, that seems like the ideal way to go: scan the parts, and print, or maybe (if required, or more economical) scan the parts and make a mold from that is then used?

I have an 87 600F sitting in my garage. Lost all the exterior bits in a fire, but keep hoping plastics will somehow become available at reasonable cost. Don't really want to cafe-racer it, and don't want to part it out if I can avoid it.

 

@NuggyBuggyCBR I didn't yet. Cold weather kicked in so the general reassembly of the bike has be suspended until I don't lose the feeling in my fingers. I will probably come back to this possibility when the thing is assembled and running again which is going to be spring at the earliest. I figure that it will be a lot easier when I can actually put test pieces against the frame and make test measurements between the mount points.

I will post back here once I give it a try.