Side cover post replacement - whats the latest?

[Andrew Vanis]

gave it a go in its simplest form and works well...and if it breaks, I'll glue another.

made them avail on flea bay at $5 https://www.ebay.com/itm/suzuki-gs-s...s/184003641565

if a GSR person wants some they are direct sale discount at $4 (add'l discount for quantity) for and flat $4 shipping to the USA (by the time one gets an envelope and pays postage it adds up to more than the item....I wonder how the Chinese sellers sell the small stuff for a few bucks including shipping)

[Dogma]

I've printed a lot of ABS, and I'd be worried about the strength of it in that application. The printed ABS won't be as strong as the original cast part. Maybe you could run an M4 screw through it to strengthen it. A PC-ABS blend might be strong enough. The aluminum angle sounds strongest to me. Maybe epoxy a printed head onto it to make a better fit in the grommet?

[salty_monk]

I would think a 3D printed piece would benefit from the same... Print a plate with holes in at the bottom of the "mushroom" so that the fixing to the cover can be stronger, that's where they always break after all.

I'd also try to add as much material as possible into the bottom section & make sure there are no sharp corners, radii are your friend

Neat project if you've got access to the kit. I have solidworks but no printer...

[Rob S.]

You can shape a piece of aluminum angle (yes it works great even though flat if you put the shape in) & glue it to the back with epoxy.

Bought covers that were repaired that way. The 'shape' usually looks like an arrow head. Worked well enough.

[Gorminrider]

I'm 3d printing a post of ABS to mate to the ABS side panel

wow- good for you out there on the bleeding edge,Andrew. I'm back here in my cave carving them out of JBWeld..which works suprising well ..you've inspired but only insofar as I can visualize a wax mold for..sigh- you guessed it! JBweld.

an internal "rebar" of metalrod or fine screen (coffee or fuel filter) too perhaps.

[salty_monk]

You can shape a piece of aluminum angle (yes it works great even though flat if you put the shape in) & glue it to the back with epoxy. Drill holes in the base part to help it bond.

[Andrew Vanis]

Not being all that impressed by posts that snapped off in normal use, I replaced mine with Dzus fasteners.
The bonus, apart from never flying off, is that thieves see them and realise the covers aren't worth stealing as they'll not fit their bike or be worth selling on.

Looks like a stout solution. What does that modification process look like?

[Grimly]

Not being all that impressed by posts that snapped off in normal use, I replaced mine with Dzus fasteners.
The bonus, apart from never flying off, is that thieves see them and realise the covers aren't worth stealing as they'll not fit their bike or be worth selling on.

[Andrew Vanis]

Last time I asked I got a suggestion of this for Hondas which seem to be the wrong size diameter for our machines. https://cyclemax.com/inc/sdetail/86/136689....plus $20 for 2 posts and and $9 shipping makes the cheapskate in my cringe.

Is anyone doing a solution that will work for us?

For my personal repair, I'm 3d printing a post of ABS to mate to the ABS side panel https://www.thegsresources.com/_foru...one&highlight=

It will be modified to accept a hairpin clip in the back to help retain it and prevent (hopefully) theft. So I'm wondering as I develop this how much effort to make it available to others to either print out them selves or at a lower price that the Hoda solution above. I'll likely make it avail to others at some point anyway and if there is current interest, I'm more likely to be diligent on this and document it as a tutorial as I glue mine on.

Thoughts and feedback would be appreciated.

Thanks,
Andy
505-304-5306

(the Orange is prototype material)