How are the hinges and latches fastened to a factory Ultra Classic tour pak? Once removed, can new hardware be installed? If a tour pak needs to be re-painted to match another color, would it be advisable to remove hinges, latches, lights and any other hardware? How much of a job is that?

 

I just check mu '05 UC. The latches are held in with Torx screws. The hinges are attached with rivets. Not sure how replacements are supplied for re-attachment. I've always preferred taking hardware off when painting, though with the rivet's maybe it would be better to mask over.

 

I would replace the stock hinges with the upgraded ones. Nice improvement when completed.

 

I've had two Ultra tour paks repainted. On both I've totally disassembled the tour paks' hardware.

The hinges are blind rivets and easily drilled out. Replacing the strap hinges with the chrome hinges HD introduced that install with screws is a major cosmetic improvement (IMO).

The latch has two parts. The part attached to the lid is attached with blind rivets; the part that attaches to the tp bottom uses screws.

Blind rivets require a special tool that few of us would have in the tool box. I tried using very small screws/nuts to attach the latch part to the lid, and the nuts hit the top edge of the bottom of the tour pak. So, I had a tech at my dealership use the dealership's service department blind rivet tool to install them.

I also removed the Ultra light bar on both occasions to paint the light bar to color-match the tour pak. It's not a difficult job to remove; just tedious because HD uses silicone to seal around the light housing cut-outs. Used a hair dryer to soften/loosen the silicone then scraped the silicone out to free the light bar and remove it. There are some nuts that also secure the light bar to the tour pak that are very easy to remove--removing the silicone is the pita part of the job.

If you are repainting a tour pak that has pin stripes, the pin stripes must be completely removed (sanded off) or they will be visible through the paint.

Carl

 

Carl is exactly correct i just did it last month. You can use small screws to replace the rivets. i just put the rubber seal around them and they do not tear up the tour pak.

 

I've seen a couple bikes with the upgraded ones. They are NICE! Those are one of those things that HD should have just put on there to begin with. Jackasses!

 

Pic of the hardware and light bar removed:

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I bought the tp lid and bottom brand new from separate sources at great prices; hence the mismatched colors

This an "after" shot with the tp on the bike:

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If you repaint the lid, you will probably want a new insert for it. HD has several and I chose the one used on the 2010 CVO Ultra:

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new style hinges

 

Well Said

 

Can't the latch be left where it is and just paint over the outside of the blind rivets?