I am on my third tail. The crack starts around the Frankenstein bolts, I get it plastic welded and then in cracks again in six months or so . Eventually I have to buy a new one as you can repair it once or twice.
I realize carrying a pillion exacerbates the problem but even so...
I was wondering if anyone has had the same problem and have engineered a solution.
What have you been using to repair it? RC51 OEM plastics are I believe a composite of ABS material so they can be mended with ABS glue (not PVC) and either pieces that will serve as inner patches or ground ABS material used in a similar fashion to fiberglass cloth and resin. Dealing with the outer surface cracks is a tad more tricky to make look nearly invisible but it is doable, especially with Honda's 3 process paints. I know lots of owners that make similar repairs to Goldwing bodywork and it holds up really well.
Duct tape can't fix stupid...but it sure helps muffle the sound
'03 SP2, '09 GL1800
Something us old dogs used to do on hard mounted parts (pegs, fairing mounts etc) to help quell vibration was using cuts of inner tube or wet suits between the hard (metal or composite) parts and it did work. Obviously some of the fasteners may not have the threaded length to put too much material between them, but might be worth a try.
A guy my local Honda shop uses back filled the mounting points with some kind of epoxy putty, used a dremel to form it so it would be flush (all inside the tail section) it hasnít cracked after a year.