[Killer Kilgore]

When I placed the cardboard over the hole. I actually put tape in hole, then cardboard, then taped the cardboard in. That way the JB Weld wouldn't adhere to the cardboard. The sides of the hole was already roughed up due the the breakage of the case. Should give an excellent surface for the JB Weld to secure to. From working with JB Weld in the past. If the JB Weld is a little thick and doesn't flow like you think it should. A little acetone will thin it out. A little goes a long long way.

While applying the JB Weld to the outside of cover. It started to sink a little. Ever so slightly. I was trying to get the outside as smooth as possible. To save time on cleanup later. Guess I was working it to much.

Before things damaged anything. Keeping the outside of cover up. I stuffed a paper towel into the hole where the bearing would sit. Then got a pop can and sat the cover so paper towel was sitting on pop can. Just to give the paper towel a little outward pressure. Then sit the other end on something to try and get the cover level.

You probably can't tell from the pic of the inside without bearing. But the is a slight curve in the JB Weld that bends to the outside.

Put bearing and seal back in. Had to get a 6mmx10mm bolt to replace the 6mmx12mm screw that had a messed up head. Looks like bearing was replaced before.

Took grinder to JB Weld and it was a little too aggressive. So finished with 120 grit sand paper.
Walmart want $5 for a can of spay paint that would be used after this. So I got a 0.99 sticker. After seeing the gouge. I found a can of black paint in back of work van. Only got pic after the 1st coat. After 3 coats it looked even better.

After paint dried. I put on sticker. Didn't need to put the sticker on. But that is what i got it for so it's on there
sticker=no smoking of belt.
But none of it will be seen after the gas tank goes back in place.

CVT and fuel tank back in. Took for a test drive. Stopping ever mile or so. Just taking it easy to break in the new belt. Everything went fine.

After test drive, went back home, put rest of plastic back on. Even replaced factory scratches windshield. Didn't really like the L channel aluminum that I used. But it was what I had and the price was right FREE.

Thanks for all the help.

[NMKawierider]

Nice work.

[Killer Kilgore]

Thank you. No doubt that others could have done better. But I'm happy with it.

Here are some more pics.
Don't know if it's the page or the phone or maybe pic size. But something acting up.
I'll try again with resized pics.

[NMKawierider]

Man do you actually have to pull the tank to get the cover off? If so...WTH were they thinking!

[Killer Kilgore]

Yep. Got to take off rear passenger wheel to make room to pull tank out.

One thing I like though. The inlet for the CVT air intake is a tube. It goes under the center console to the hood.

It would be easy for someone to add a 3" bilge fan. If it had enough CFM inline. Then a snorkel or a hood scope 😂 and add a filter.

I got a bilge fan that pushes 320 CFM and a filter just haven't done it yet.