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Broken sidecover tabs

  • Thread starter Thread starter ddeboer
  • Start date Start date
D

ddeboer

Guest
Hi...my beloved 1983 11000E has the tabs broken of the left sidecover :(. Does anyone know if these can be reattached?
I've never pastic welded anything.

Thankyou!
 
2-part epoxy called grip-gaurd for plastic its 40 bucks a tube grind a v shape where it broke front and back tape one side so it holds the piece in place after mixing the epoxy spread on the v grove u made wait till it get hard then apply to back side wait till it gets hard they have a 5min stuff sand smoth then paint stuff works damn good
 
Jim,

Yes! That looks like a much simpler process. Nice work. Thanks for sharing.



Thank you for your indulgence,

BassCliff
 
if u wanna reinforce the tab use a mesh like the one u use for drywall (ive used drywall mess before) ruff up the area with a 80 grit frinder (tab dosent have to be broken) use the plio-grip like i said earlyer if anyone wants a long type up of how to do this pm me with plio-grip in the title
 
Side note - a little WD40 on the rubber washer when reassembling helps that post disassemble a little easier the next time. Has helped to keep mine from rebreaking.

Edit: Just read that thread Posplayr posted, and I like the vaseline idea better. It'll last longer than the WD40.
 
Last edited:
Also

Also

Also, the rubber grommets that the tabs fit into get really hard and brittle after so many years. I replaced mine on both of the GS's and it made the tabs slide in and out really easily.

You can order them just like any other OEM part. (I tried to find some that would work at the hardware store but was unsuccessful.)
 
I drill a pair of 6 mm holes in the underside of the cover adjacent to the post and zip tie the cover to the frame tube. This stops them being lost to the wind (happened) and prevents them being stolen (happened twice). If a post is broken off, this method works good for keeping the cover in place.
 
I have reinforced "good" posts, as well as improving broken posts, by drilling small holes through the posts themselves and "dimpling" the side cover around the posts (without going through) in order to give the stronger epoxy a better grip on the cover and an "anchor" through the posts. This repair has never failed on me.

I have to admit though ... I LOVE the idea of using a through hole and a zip tie to prevent easy theft or loss of the side covers!

Regards,
 
Last edited:
In reality, how many of us are there out there looking for side panels for these old dinosaurs to steal?

But I do like the idea of a secondary retainer in the event the post breaks while riding, preventing accidental loss.....
 
Smokinapankake said:
In reality, how many of us are there out there looking for side panels for these old dinosaurs to steal?
Click to expand...
I've had side covers stolen off my bike in the past ... so don't put it past someone to grab something they want... Better safe than sorry!

Regards,
 
A slight modification to my previous post, is to cut the plastic pin off all together and replace it with a stud or bolt of slightly longer reach secured in its place with two mix epoxy, which then pushes through the rubber grommet, you then secure it with a flat washer and nut from the inside.
That way it is very secure and cannot be seen from the outside, preserving the original look of the cover with no holes drilled and bolt heads visible from the outside.
 
Last edited:
Flyboy said:
A slight modification to my previous post, is to cut the plastic pin off all together and replace it with a stud or bolt of slightly longer reach secured in its place with two mix epoxy, which then pushes through the rubber grommet, you then secure it with a flat washer and nut from the inside.
That way it is very secure and cannot be seen from the outside, preserving the original look of the cover with no holes drilled and bolt heads visible from the outside.
Click to expand...

Ok seeing your last idea, I will continue on with
101 ways to fix your side cover tabs............


You could epoxy one end of this quick release into the cover and use the other side to hold through a frame mounted metal tab or use as a tab.

http://www.harborfreight.com/general-merch/hardware/quick-release-key-ring-32864.html

Same idea but just use one of these instead of as a bolt and put the pin in to secure the cover

http://www.harborfreight.com/general-merch/hardware/74-piece-clevis-pin-assortment-94460.html

Since I put in aluminum tabs, it would be a simple matter to drill through and use one of the Hitch Clips. I kinda like this. I have never had an issue with one of my covers falling off and I don't want to have to use a wrench to take off the cover and I have already fixed it anyway.

Anybody else :-\\\


picture.php



picture.php


Hitch Clips: good for axles instead of cotter pins

http://www.harborfreight.com/general-merch/hardware/150-piece-hitch-clip-assortment-67557.html
 
Good Idea there, further on my post.....
102 use a wing nut as opposed to a normal nut, no wrench reqired.
 
Flyboy said:
Good Idea there, further on my post.....
102 use a wing nut as opposed to a normal nut, no wrench reqired.
Click to expand...

I went and looked at my GS1100ED and it hard to get to any of the tabs under the covers. Also the covers are actually held on with my Corbin seat. So I'm good I think ;)
 
More people steal them old side covers then yould think. I had a buddy who had his KZ650 up for sale in a lot & came back to find the side covers gone. First thing I thought is who even wants a KZ650 let alone the side covers. If I take my 1105 KZ1000 out to run the snot out of it I take the side covers off first or they will blow off at high speed.. Since then I drill tiny holes for small cotter pins in the ends
 
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