Rebuild / Repair a PWC Throttle Lever

From time to time recreation vehicle parts break or fall off.
In this instructable I will show how I repaired a smashed throttle lever from my Yamaha Wavejammer, using JB weld epoxy to build up missing parts and reinforce with fiber glass.

For this instructable you will need

JB Weld epoxy
Tooth pick or skewer
Popsicle stick
Fiberglass fabric
Fiberglass resin
Resin hardener
Protective gloves ( latex or nitrile)
Sheet of paper
Roll of tape
Disposable plastic container
Non stick material ( sticker backing )
Denatured alchohol
Primer
Top coat paint
200 and 400 grit sandpaper
Hobby knife

Start with the pieces which fit the best first.
On the paper, mix a small amount of the epoxy big enough for the pieces you are working with.
You will need to epoxy the pieces several times before the rebuild is done.
Once the epoxy is fully mixed, apply a small amount of it with the tooth pick to the edges which are to be joined. Use equal amounts from both tubes.
Press the pieces together and let sit to cure for minimum 12 hours to fully set.
Some pieces may need to be taped together in order to set straight.
Resist the urge to touch it until it has fully cured.

Once the epoxy has cured continue with the rebuild,
Sometimes as with this lever some pieces will be missing. You will need to build up the material.
You can use several materials to build it up,
I chose to continue using the epoxy as it is quite strong and I will be reinforcing it with fiberglass.
First tack the pieces together with a spot of epoxy and let cure.
Once cured, cut a piece of non stick material ( Teflon fabric works, if you have some. I used the backing from a self stick label) which fits the void area which you wish to fill.
Apply the piece non stick side up to the edge of a length of any sticky tape wide enough to cover the void.
Stick the tape on the part you are working on with the non stick side to the inside of the repair. Mix some more epoxy and fill the void paying attention to the edges and thickness, making sure to push into all cracks where the non stick material meets the pieces.

Once the epoxy has cured again remove the tape.
the non stick material should just peel off much easier than the tape.
the epoxy may be too thick or over the edge trim it back with a hobby knife and some sand paper.
You are now ready for the fiberglass.

Even though the repair looks and feels nice and strong it will not stand up to the repeated use on the jet ski, so it will need some support from a layer of fiberglass.
Cut a piece of fiberglass fabric large enough to cover the surface of the part.
Mix a small amount of resin in a disposable plastic container ( follow instructions on tin)
wear your gloves to adjust the positioning of the material on the part paying attention to removing air bubbles.
Be warned its sticky and gets everywhere.
Let the part cure , the cure time is much less than the epoxy and should be fully hard within an hour. cleanup is with soap and water if you got some on yourself.

once the resin has cured and been trimmed, the part is ready for sanding and finishing.
Use 200 grit to remove rough bits and edges
Use 400 or better for finish.
once complete it is ready for painting.

The next thing to do is clean the part with denatured alcohol and give it one coat of primer. Let it dry according to the instructions on the can.
If you have covered the pin holes drill them put now before the top coat.
Give the part a light sanding with the highest grit sandpaper and clean with denatured alcohol before the top coat.
Paint the part with your top coat and let dry.
I used a metallic blue to match my ski.

Once the part has fully dried you can reinstall it. and go have fun,
or in my case.. wait for spring, then go have fun.

I hope this project was informative and is helpful.
Thanks for viewing.