What structural adhesives will bond a crack in the body fender? I think the it is polypropylene which is hard to glue. What about a plastic welder?

 

this may sound redneck, but i have taken my soldering iron and "welded" some plastic back together on my polaris. it worked! just my two cents.

 

An air powered plastic welder will do a nice job if you take your time and do it right. You should be able to get a compatable polypropolene rod to use as filler. I used to do it a lot at my old job, best to run a "tacking" tip to meld the plastic back together, then you use the rod and welding tip to fill and reiforce the repair. When I welded my son's LT80 fender, all I had was white rod for his yellow fender, what I did was one slow deep pass on top, the white and yellow blended pretty good, then I turned the fender over and did a tripple pass on the backside out of view, it was strong as ever, and didnt even look too bad. spend a little time cleaning the break with alcohol to degrease it, and if there are any rough spots, flatten them out by shaving them down with a razor blade.

 

JB weld will bond anything. Used it for cracked blocks, everything. well almost anything : Click Here
I have also drilled holes on either side and run zap straps through. depends on how pretty you want it.

 

JB will bond well, but it is meant as a solid repair, you can ever grind and drill it, I would think that it would be too stiff for a fender repair, and crack out if flexed like a fender can be.

 

I have done the best of both: On the underside I used JB weld on the top side an inexpensive plastic welder with the clear rod, then buffed it smooth. It matches well enough that no one has ever noticed it (I can still see it, of course). But more importantly, it's held up for several years of rough trail riding and I $aved a lot not having to replace the severely broken front (in pieces) cargo box and cracked rear fender.

 

Shoo Goo works pretty good to. Like silicone but way tougher. Would likely need replaced to 2 or 3 years but easy to apply.
Ken

 

I ripped one of my floorboards and I'm just going to give the whole machine back to Polaris rather than fix it.