i would take a piece of 1/16" aluminum sheet, 3" x 14" and contact cement (super 77 maybe) it to the inside of the tour pack. tin snips to contour around the hinge if needed, drill the 2 lower rivets and put small chrome nuts and bolts in a line down the 14" and the 4 lower rivet holes. This will hold it together for a long time.
Get a pastic epoxy, Loctite and JB weld make one, among others.
Take a dremel and create a "V" along the crack, use a coarse grit sandpaper to roughen it up, then denatured alcohol, starter fluid on a rag, etc., something that will clean the dust but leave the surface dry as a bone. Obviously, careful around painted parts.
Prep and dry/bonding time are everything.
Had a crack at my hinge on my tour pack. Too many hard opens slamming it against the cable, lesson learned.
Here's pics of mine. Is it body shop quality clean and gorgeous? no. Absolutely not. But My bike is ridden and has it's share of nicks, scratches, etc., the crack hasn't spread a millimeter since the repair. I hit it with a bit of touch up paint...
Looking at the previous post reminds me that you can drill out those rivets to give you a better shot at the repair, then use screws or source the OEM rivets from HD to reattach when you're done, if that's appropriate for your repair, OP. Good job on that repair, dajogejr! Ya got the job done, and it's a WHOLE lot better than spending a grand on a new box!
That is literal the type of crack I have; almost same location however mine goes through the middle of the hinge.
That being the case you'll definitely want to incorporate a metal brace thru the middle of your repair. Remove the hinge as I described, figure out the method of repair depending upon the material your conna use, then afterward, redrill the holes for the hinge and reattach. You'll actually have something that was stronger than stock, and if you wanna go all OCD on it, do the other hinge at the same time.
If you have the skills and equipment, you can drill and tap holes for the hinge attachment screws into the metal brace for a cleaner inside appearance. Be cognizant that you may have some clearance issues with the screw heads, which can be mitigated by using different design screws, like panhead screws, or simply grinding down the screw heads until the hinge closes like it should.
2005 was the last year for the tour pack to be fiberglass 2006 and up are ABS
Fiberglass will still adhere to ABS with proper prep, and will reinforce/repair the crack. Do it inside, then file and fill the outside n paint. Not a body man, but pretty sure that would work fine.
Fiberglass will still adhere to ABS with proper prep, and will reinforce/repair the crack. Do it inside, then file and fill the outside n paint. Not a body man, but pretty sure that would work fine.
Yep. Just so. Have done it several times my own self with excellent results.
04-13-2017 | 11:46 PM
