Side cover post replacement - whats the latest?

[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/_for...s-anyone-do-a-3D-print-file-of-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)

 

[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]

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?

 

[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.

 

[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.

 

[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.

 

[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...

 

[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?

 

[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-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)

 

[Rich82GS750TZ]

I'll be buying 2. That's great Andrew. Thank you for your service to the cause (our aging GS's).

 

[Andrew Vanis]

I'll be buying 2. That's great Andrew. Thank you for your service to the cause (our aging GS's).

COOL! Thanks! paypal to AndrewVanis@gmail.com (please "Send money to a friend" to avoid PayPal charges include your address in the note)

here is the GSR pricing plus flat $4 shipping to USA and actual to the rest of the world

1 at $4 = $4.00 each
2 at $7 = $3.50 each
3 at $10 = $3.33 each
4 at $13 = $3.25 each
5 at $16 = $3.20 each
6 at $18 = $3.00 each
7 at $20 = $2.86 each
8 at $22 = $2.75 each
9 at $24 = $2.67 each
10 at $26 = $2.60 each

PS - these are to OEM dimensions not the extended for the clip. The clip is a great idea but (at least in my case) I couldn't insert the clip with the cover on the bike as reaching around back was too difficult.

PS2 - replacing the aged rubber grommets that these insert into will make installing and removing your existing ones and these new ones WAY easier!

PS3 - when removing, its easier on the panel and the post if you can push out the post from the back if you can get your finger in there.

 

[Rich82GS750TZ]

PM and payment sent.

On one of my side panels, the pin is broken off flush with the panel. On the other, the pin took a chunk of side panel plastic with it. Previous attempts to glue the broken pins on were unsuccessful. What is the recommended adhesive product/technique?

nevermind, I just read this "standard ABS plumbing glue."

 

[Andrew Vanis]

PM and payment sent......nevermind, I just read this "standard ABS plumbing glue."

thanks, package mailed.

yep, ABS glue works really well. if your cover is painted where the post is, scrape off the paint so the chemical reaction can bond. Also, I have found the ABS glue a great glue and filler for cracks an to reinforce the back of cracked panels with a piece of ABS plastic (most plastic is ABS. this pic shows a piece of plastic I cut that came from a old monitor stand) if the ABS glue melts it then it should bond. FWIW, I tired using Acetone to glue the 'crack' and it kinda worked. the ABS glue is better....eventually I'll get to a proper fill, sand, and repaint on this cover.

 

[salty_monk]

....I wonder how the Chinese sellers sell the small stuff for a few bucks including shipping)

It's actually very simple. The Chinese post is subsidised as "a developing economy". That means USPS are not allowed to charge them the real costs which means the rest of the post is subsidising that...

 

[Rich82GS750TZ]

Nd my gas tank

Nd my gas tank

Got my pins, thanks Andrew.

So, here?s what I have. Both flat tabs of both panels are in good shape. They?ve been holding the panels on for quite a while. Round pin from right panel had been detached and living in the rubber grommet for so long, I forgot it was there. A previous attempt to glue it had failed, don?t remember what I used, probably crazy glue. There?s a cross shape in the plastic panel that shows me exactly where I need to try to glue it using ABS plumbing glue. And I can use this pin as a guide to cut one bought from Andrew, with one to spare. I even found 2 new round grommets that are still very pliable. Must have bought extras a while ago.

The left panel is going to need a bit more work. My previous repair failed, that pin took a chunk of the panel with it. So I?m going to have to fill that. My only experience with body work is on these panels and my gas tank. The panel was cracked around the base on the pin. I repaired it with filler, bondo, something, don?t remember. It?s the red you see up in the pics. I had the panels and tank professionally painted, and they look pretty good, except where my failed repair took that chunk out and caused the paint to crack.

So I think I?ll sand and repaint both panels some complimentary color after repairing the pins. Maybe I?ll make some custom vinyl GS 750TZ decals. Not a fan of the look of the original T badges.

Any advice on how to fill the hole under where I need to glue on the new pin?

 

[Andrew Vanis]

In your case, you may have to remove the old glue/filler you have in there first with a Dremel or something so the abs glue bonds well.

that cracking on the outside makes em wonder if the pain is peeling. In any case, remove all the loose stuff because anything glued to that will be weak.

Depending how that crack is you may consider gluing a ABS flat plastic backing plate to reinforce it from the inside (see my pics above) and then gluing the post to that. That will also give you something to fill to from the front side. I like how ABS glue dries up as a filler.

For the existing one you have, when you glue it do a few glue layers. One to attach and then subsequent ones as a gusset.

The following is how I addresses mine.

I had a hole in my side cover where the broken post was because a bolt was used to keep the cover on. When I glued on the post, I put a piece of tape on the outside if the cover, the hole got filled with abs cement as a part of the post for on process. Next day I pulled the tape off and the hole was filled..... And since I had a black cover it looked fairly good.

 

[salty_monk]

I think you can dissolve some ABS & use it as a filler.. You need it to be ABS so that the glue you're using works on the post. This is one reason I am a fan of having a perforated base plate on the new post. Makes for a stronger fix.

 

[Andrew Vanis]

I think you can dissolve some ABS & use it as a filler.......perforated base plate on the new post. fix.

The ABS glue dried seems to make a really good filler. I wonder if the glue is just acetone with dissolved ABS already.

A bse plate is challenging on a retro fix like this. it would have to be engineered to ever bike and, likely, to every situation - just look at the two covers sampled right here. The Blue one need something (almost) flat and my 750 goes up at 45deg on one side.

The ABS glue seems to make a good glue and filler so that each post can be modified as your situation requires and if you don;t get it 'just' perfect, the filler quality of the glue makes up for any imperfections.

Mine is still holding up well.

 

[salty_monk]

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. You can see they tried to address these breakages with webs on the later side covers.
I'm an industrial designer by trade, I tend to err on the side of caution.

The existing stub can be ground flat easily with a dremel if it sticks out where it broke...
I would think it easier to adapt the cover to match than the new post if that makes sense.

It's great that someone is thinking about these things. These have always been a problem

 

[Grimly]

The ABS glue dried seems to make a really good filler. I wonder if the glue is just acetone with dissolved ABS already.

ABS porridged into MBK solvent, as far as I know.
Just going by the ABS / PVC pipe jointing glue that's available here - that's what it is.