Side cover post replacement - whats the latest?

[Andrew Vanis]

I think the plate would flex to cover all these eventualities if you didn't make it too thick and chamfered it into the post for strength.....
I'm an industrial designer by trade, I tend to err on the side of caution.....It's great that someone is thinking about these things. These have always been a problem

Bigger could be better in this situation though not feasible considering the design differences in applications. Just look at my 750 side cover that needs a post about 1" long and the 550 cover that seems to take a 1/4" post. and then there is that my 750 cover is half on the flt and half on the angled side and the 550 is flat.

Such a solution would take a dedicated design for each model which would take tons of inventory and even more so, a lot of design time with access to every side cover to match.

having the user shape them to their application is the way to go.

And the thing to keep in mind is that the replacement post as provided is holding up really well and is already stronger than OEM with its circular base vs. the minimal OEM X base.

Thanks, I hope these replacement posts provide some headache relief for our users.

 

[2BRacing]

….. I hope these replacement posts provide some headache relief for our users.

Well done, great to see modern 3D printing technology being applied to solve "old school" issues!

 

[bonanzadave]

I used some plastic automotive body molding push pins glued on with JBW plastic. Works great !!

https://www.amazon.com/Dophee-Faste...ocphy=9019573&hvtargid=pla-309781252223&psc=1

 

[wymple]

I used some plastic automotive body molding push pins glued on with JBW plastic. Works great !!

https://www.amazon.com/Dophee-Faste...ocphy=9019573&hvtargid=pla-309781252223&psc=1

And on the help racks at any auto parts store. They are very useful. I often use them to keep older or broken door panels in place.

 

[Rich82GS750TZ]

So, I finally got to working on the round pegs on my side panels. One new ABS peg bought from Andrew Vanis (thank you) and one original that had just broken off. This Black ABS cement is some pretty great stuff. Looks like it should do the trick.

Because the left panel peg had completely broken out, I used the right panel as a guide to mark the left, covered the gaping hole with tape and marked the center.

Drilled a clean hole just slightly larger than the new peg. And cut the new peg to length plus the thickness of the panel by chucking it in the drill press and using a hacksaw blade.

I covered the front of the hole with wax paper and taped on a flat stick to hold a puddle of cement in the hole.

When it was dry (waited a day), removed the stick and wax paper. looked pretty good. Pooled more cement on it (waited another day), then sanded it wet, a few different grits.

Except for this panel, my paint is in pretty good shape, so painting isn't in my immediate future, and I had this sticker that I got from another member (thank you D Roberts). I've refrained from any decals on the bike up to this point, but with all the help and advice I've gotten from the members here, I don't mind advertising.

(not shown: I've also pooled up more cement around the base of the peg on the inside. And I've used the same cement to re-glue the original peg in the right panel.)

Should be good for another 38 years. COME ON SPRING!!!

 

[Andrew Vanis]

So, I finally got to working on the round pegs on my side panels. One new ABS peg bought from Andrew Vanis (thank you) and one original that had just broken off. This Black ABS cement is some pretty great stuff. Looks like it should do the trick.

(not shown: I've also pooled up more cement around the base of the peg on the inside. And I've used the same cement to re-glue the original peg in the right panel.)

Should be good for another 38 years. COME ON SPRING!!!

Rich, that looks great! The sticker is a nice touch Like It! Andy

 

[Andrew Vanis]

Hey guys,

Want to let you know if you placed orders on Ebay they will ship shortly. With this corona thing I was stuck on a sailboat w/o a country that would accept us and after sailing for a few extra hundreds of miles (which took a while at 3-4 knots) to a US territory that would I just got back to the sates last night.

Andy

 

[Rich82GS750TZ]

Wow Andy. Glad you made it home safely.

 

[Guest]

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-side-cover-post-replacement-70s-and-80s/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)

The Chinese gov subsides postage for export sales. From point to point in China isn't cheap. That is a great idea, I am working on printing a custom 1/4 fairing for an 82 1100E

 

[Guest]

I have an '83 GS1100e and I struggled with broken tabs for quite awhile. I tried multiple ways to create tabs and they all failed. I think I found a way to make tabs that are sufficiently strong to withstand the rigors of the side covers being removed and replaced multiple times. A good hobby shop will carry a wide selection of plastic stock. I beams, channels, square and rectangular shaped long pieces. I think you can find a piece whose width and thickness is close to the width and thickness of the tabs on the bike. You can cut an arrow shape at the end and then make the length along as the tab on the bike. The hardest part is getting the new piece to line up with the hole on the frame. If it's off just a little you will not be able to get the side cover to fit flush with the tank. If you need to modify the shape it can be done with a modelers hacksaw and a file but a dremel rotary tool is the easiest. To attach the new tab to the side cover use JB weld. Nothing else I tried was strong enough. If you want to get creative you can add some reinforcement pieces. This has worked for me but It's wise to be gentle especially when taking the side cover off. I hope this tjp can help you keep those side covers secure. I don't know if this method has already been suggested, but I thought it might be helpful.

 

[Rich82GS750TZ]

Andrew

Are you still making and selling these pins I bought from you? Mine are holding up great. I’d like to get 4 more to repair the broken-off pins on the panels on my kid’s dirt bike.​

 

[Suzukian]

I found some pins off of another piece of plastic, and thought, cut down, they could make great posts. I cut them down to size, and made a little dam around them (around 1") in diameter with the post in the center, dam was made of tape., filled it with J-B-Weld, and put the post in the position I had marked for it. It has lasted 5 years so far. The J-B Weld really grabs the plastic, it leaked a little under the dam, but I think that strengthened it. Anything plastic that will fit and wedge tightly into the hole will work.

 

[Rich82GS750TZ]

I found Andrew’s eBay listing.
https://www.ebay.com/itm/185241664824

These worked perfectly so I’ll get as many is I need for the kid’s bike and probably work on it over the winter. That and some paper models which I’m sad to say have gone untouched for over 6 months. Too busy for all these hobbies.

 

[Suzukian]

I have around 4 Terabytes of paper models on my list. Some I have to finish , they are unfolded, I just have to make instructions for them.

 

[Andrew Vanis]

I found Andrew’s eBay listing.
https://www.ebay.com/itm/185241664824

Thanks for finding that! Glad these have been helpful for y'all. They are still available. ordering off eBay works and is easy and you can also always email me directly for a direct sale and save some pennies that wouldn't have to go to Ebay/Paypal.

AndrewVanis@gmail.com

I also periodically receive requests for longer ones, etc. and all that is possible so get in touch and we'll see what we can make for you.

Andy

 

[schneider]

Yet another piece of the puzzle I am working on. I ordered a side cover that was missing the post, I didn't catch that when I ordered it. anyways I find one on Ebay a guy is printing and it turns out he is a member. Thanks Andrew for the post, I will put up some pics soon. Any idea on the proper length for a 1979 850?

 

[Rich82GS750TZ]

Andrew’s posts come longer than needed. If you have an intact post on the other panel you can get the length from that. The pins and ABS Cement repair I did 4 years ago are still holding strong.

 

[oldGSfan]

Andrew’s posts come longer than needed. If you have an intact post on the other panel you can get the length from that. The pins and ABS Cement repair I did 4 years ago are still holding strong.

I just put one of Andrew's posts on. Cut down, prepped the mounting area with Dremel and used black PVC cement. It's solid. I also had a couple of broken ones along the top, the arrow-shaped post. I saw the thickness was very close to the ABS pipe I use for setting fork seals, so I cut off a bit, cut it in two, put it in the vise, and heated it with my heat gun. That flattened it out easily. A little Dremel and emery cloth work and it matches the other and also is plenty strong.

 

[Andrew Vanis]

Created these flat side posts based on a request. Get I touch if something like this could be helpful for your bike. This was for a e1100. More pics avail but seem to be limited to one attachment per post.

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Email is best AndrewVanis@gmail.com