side cover repair

[mark81]

The tab on my side cover was broken and missing when I purchased the bike. the side covers had been screwed into the center cover and chrome caps over the screw heads. That's one way to skin a cat. I thought I'd try another since it was a bit inconvenient to remove screws when I wanted to remove side covers.

it really is an easy fix that takes about 10 minutes total.  just take a heavy duty paperclip and slightly bend to fit, lightly scuff the surface and hot glue it to the cover and you're done.

paper clip


scuffed surface (you can see where it had been previously screwed together)


test fit


hot glue



strength test with 40 oz hammer



Hot glue is an underestimated underused adhesive. I have found it more convenient to use and has a stronger bond than most 2 part epoxies. however in this situation with the engine heat and it being mid august we will see how it holds up. update to come 

[Fazer]

Cool fix.  You must be some kind of genius! 

[doubletee]

Great idea! I'll, too, be interested to hear how the hot melt holds up in the summer engine heat.

[pancho]

Cool fix.  You must be some kind of genius! 

+1

[gordonv]

Nice, I like the heavy metal from the paper clip. If you don't like the hot glue, try pouring over some ABS glue instead. Mine is dried out (forgot to close the lid), would most likely be good to use for this fix.

[Tfrank59]

That's a pretty good idea to fix it, though I am somewhat leery of using only epoxy (without some sort of threaded fastener as well).  My bike had the same issue when I bought it, so I just fabricated a little aluminum replacement tab and fastened it with a button head stainless screw (from the outside) and then painted the head of the screw to match the side cover. The whole fix took about 15-20 minutes and it's stronger than the original.

[mark81]

this is how it was originaly held on. there is a screw through the side cover into the center cover with a plastic button. chrome cap snaps over screw head onto button

[mark81]

Just did a bit of research on this glue. Application temp is 250-375F  softening point is 176F.  it will probably get soft but not remelt. if I have any issues I will clean out this glue and use ???? whatever I find in my basement I think might work. A big glob of rtv will withstand the temp.  I've repaired side covers on other bikes with legos and a soldering iron. duct tape will match the chrome close enough 

[Fazer]

Mark--JB Weld if your hot glue does not hold.  That stuff will fix an engine block.

[old2soon]

Black A B S hardening. It's sandable and paintable-but in this application NOT an issue. Repaired a cracked-multiple cracks-saddle bag with this stuff. Mine has screws BUT the wind will NOT take them off!  Used the Velcro repair the first time-but didn't like it. RIDE SAFE.

[Fazer]

His side cover is chrome, not ABS. 

[Bighead]

Nope still ABS.

[The emperor has no clothes]

His side cover is chrome, not ABS. 

Its just a chrome coating over the ABS.

[Gavin_Sons]

You are a genius.    ill have to remember this one. U coming to the Dragon Round up next month?

[mark81]

You are a genius.    ill have to remember this one. U coming to the Dragon Round up next month?

Goong to try to scrape together some money to make it

[Fazer]

Chrome over ABS???  Well OK, I stand corrected.  I just sold an 89 Shadow that had real chrome side covers.

[Gavin_Sons]

Chrome over ABS???  Well OK, I stand corrected.  I just sold an 89 Shadow that had real chrome side covers.

just like the alternator covers, chrome over ABS.

[Chrisj CMA]

Chrome over ABS???  Well OK, I stand corrected.  I just sold an 89 Shadow that had real chrome side covers.

lol, real chrome...as opposed to fake chrome......or maybe just chrome on metal instead of chrome on ABS?   

[Bighead]

Chrome over ABS???  Well OK, I stand corrected.  I just sold an 89 Shadow that had real chrome side covers.

You are correct the older shadows had real metal chromed side covers my 96 had em too but the valk's are ABS.
Also if they were metal not likely to have broken.

[da prez]

J B weld will stick for a while. ABS and only black ABS will hold. I have repaired many bags and parts.

Some will say I am wrong , but I have a lot of experience with covers and bags.

                                  da prez

[mark81]

The chrome "plating" is on the inside too. Dont know that the abs glue will be of any use inless i remove the chrome to get to the plastic.  I've put a few hundred miles on it in the heat and no issues with the hot glue yet. Ive seen hotter days though and that has me a bit skeptical of the longevity of my repair

[rockbobmel]

The tab on my side cover was broken and missing when I purchased the bike. the side covers had been screwed into the center cover and chrome caps over the screw heads. That's one way to skin a cat. I thought I'd try another since it was a bit inconvenient to remove screws when I wanted to remove side covers.

it really is an easy fix that takes about 10 minutes total.  just take a heavy duty paperclip and slightly bend to fit, lightly scuff the surface and hot glue it to the cover and you're done.

paper clip


scuffed surface (you can see where it had been previously screwed together)


test fit


hot glue



strength test with 40 oz hammer



Hot glue is an underestimated underused adhesive. I have found it more convenient to use and has a stronger bond than most 2 part epoxies. however in this situation with the engine heat and it being mid august we will see how it holds up. update to come  

Hey Mark, What is the distance from the clip outside to the edge of the cover? Is the clip bent?

I have the same parts to do the fix you did. Does it fit tight? Thanks,  Bob

[Hook#3287]

Cool fix

Hot glue is excellent for adhesion.  I use it to help anchor crown molding over cabinets.

My only concern would be the different rates of contraction and expansion between the cover plastic and the glue.

Everything contracts or expands due to temperature changes and if the glue is more or less stable than the cover, it will eventually release.

But, it could hold excellent for years, maybe decades.

Seems a periodic inspection of the glues "holdness" would be a good thing.

I used the velcro fix over 15 years ago and it's still working.   

[rockbobmel]

I didn't do the repair yet, but I got some OATEY medium black ABS cement that seems to be equivalent to Weld_On brand.
https://www.oatey.com/2373626/Product/Oatey-ABS-Medium-Bodied-Black-Cement

I'm trying to figure how much bend for the clip to fit tight while not exerting side to side pressure.

[Hook#3287]

I didn't do the repair yet, but I got some OATEY medium black ABS cement that seems to be equivalent to Weld_On brand.
https://www.oatey.com/2373626/Product/Oatey-ABS-Medium-Bodied-Black-Cement

I'm trying to figure how much bend for the clip to fit tight while not exerting side to side pressure.

Bob, if your other cover is good, use it to get a feel for the distance the clip needs to be from the cover .

[rockbobmel]

  Thanks!

[Jims99]

I have not had good luck here in Florida with hot glue. I've used for a temporary hold, but over longer periods it will slowly release.

[mrgeoff]

Just for information only...did you know that if you put baking soda over wet super glue, it hardens instantly and bonds stronger...it can be filed down but takes a lot of filing...use a dremel tool...try it on something else so you can see how it reacts and you can judge on much glue / baking soda you might need...just thought I would put my 2c in...!!!

[rockbobmel]

The baking soda/super glue is a great secret!  That can even be used on guitar string nut repair.

https://www.youtube.com/watch?v=slCMkvEfK_U

[Valkpilot]

J B weld will stick for a while. ABS and only black ABS will hold. I have repaired many bags and parts.

Some will say I am wrong , but I have a lot of experience with covers and bags.

                                  da prez

+1

Most adhesives on ABS will give way over time. 

The Oatey's Black ABS cement works because it is ABS in a solvent carrier and the sovlent disolves the receiving surface and chemically welds the two.

[Savago]

Nice hack!

[rockbobmel]

Got the other cover home to compare the tab opening.  Did a little clip bending , sanding and got it welded on with the Oatey's ABS (4 coats).

Sorry, I'm still pic-illiterate  ???

[da prez]

  I use the oateys abs glue. D O not try to use the multi purpose glue. It will not work. I have also filled the seams on bags and crack repair. I also re glued the joints on the inside of the bags. This was just done as a just in case. JB weld and bondo will not stay as a repair on ABS plastic. I also buy it in the small cans as it tends to dry out with contact to air.  One of my next purchases is a plastic welder. Yes , I know a soldering iron can be used. I do use one. A good plastic welder has a preheater.

                                 da prez

[MarkT]

I just use a small wire tie and a couple holes.  Not very noticable, very durable and easy to replace if it ever breaks.  Bonus, it acts like a hinge when you pull the cover off.

[recman25]

  Mark81, thanks for sharing that fix! I just did it with my '99 Interstate. I dry fit it with duct tape to get the bend just right. When i was confident it would work out, I used crazy glue and baking soda, and a little prayer! Works perfectly!! You just saved me and countless others around $300 for a part that is on a national back order, and probably no longer available

[mrgeoff]

You should see what I can do with a tooth pick...Just kidding...Nice to know somebody that is thankful...!!!

[mark81]

Hey Mark, What is the distance from the clip outside to the edge of the cover? Is the clip bent?

I have the same parts to do the fix you did. Does it fit tight? Thanks,  Bob


[/quote]

Not sure of the distance i guessed put a dab of glue test fit and repeat if necessary yes the clip is bent to follow the contour of the cover. Fits tight.  Been almost 2 years and 20k miles had the cover off and on a few times since then. no issues with the repair whatsoever even in the summer heat after riding 800 miles in a day still held strong.

  Mark81, thanks for sharing that fix! I just did it with my '99 Interstate. I dry fit it with duct tape to get the bend just right. When i was confident it would work out, I used crazy glue and baking soda, and a little prayer! Works perfectly!! You just saved me and countless others around $300 for a part that is on a national back order, and probably no longer available

Thats what this place is all about. Helping keep theae bikes together and looking good. Well that and political discussion.

[Whattimisit]

I just had the other side of the tab break off on mine. The cover right where the key is. I haven't had time to fix it yet, but maybe I can do something like this too. Thanks for the ideas.

[rockbobmel]

I'm very satisfied with the results I got.  Just like the pics above but I used ABS "Black" cement.

[rockbobmel]

Got pics finally.