I'm in a similar situation, and from the input I've seen so far, it's going to mean alot of elbow grease. I'm stripping/repainting an '85 bike. Tank, and a few pieces of plastic fairings. So far the best way I've found to strip it down to plastic, is with the help of a mechanical stripper. I was browsing through ACE Hardware and came across the following:
San Buf Flap Wheel...basically it's a plastic wheel with short sandpaper strips attached to it, that when attached to a hand drill spins the sandpaper to help strip, it comes in several grades, from Coarse to Fine. As a trial I picked the Medium, and so far has cut down on the amount of sanding hours to a minimum. I will have to sand the plastic with some very fine paper to get the smoothness back, but it cuts through the three old layers of paint and the decals, with little problem, since the sandpaper strips are plyable, it conforms to the plastic and pressure applied. this has worked well for me so far. I couldn't pass trying it for the $5 or so I spent on it, compared to other alternatives. My time is worth more than that.
I would appreciate any other tips on restoring plastic pieces.
I'm also going to be stripping and painting the tank, so far this is my plan of action:
1. Chemical stripper: to remove the three coats of paint including the factory coat, and the decals that have been painted over.
2. Wetsand in progression down to bare metal. Bondo the few small imperfections on the tank, dents and such.
3. Prime the entire tank.
4. Basecoat of dark gray or so, wetsand in between coats to remove imperfections, runs or anything I don't like in the paint and recoat.
5. Clearcoat, Wetsand and Recoat.
The trick is I have no paint gun, can't afford a PRO paint job, and don't want to buy expensive paint guns for this one time. This bike needs alot of TLC in other areas, like engine and mechanical care, and that is where I'd prefer to spend the majority of my time and money, if any.
Any recommendations as far as DIY paintcanning the parts? Any particular brand of canned paint that is better? Any tips for paintcanning a project like this?
TIA.