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I am in the process of resurrecting my '09 FLHRC that had an unfortunate incident with a deer last summer. The bike is/was totaled by insurance and I was able to by it back at the auto auction for a really decent deal. The frame and forks are straight, the motor runs so it was pretty much a re-tin job with a few tweaks here and there. The left side saddlebag support mount was bent a bit, but I heated it and got it straightened it out pretty easy. The last thing that I have to do is repair the area where crash bar mounts at the top. Below are a couple of pictures of what I am dealing with. The original crash bar did its job but got bent really badly in the process. The mount location was bent outward a bit and when I was flattening it the bent spot just broke out completely. I was thinking of just getting the local custom shop to weld a plate across the tubes, over the stock unit, paint it up and off I go. Does anyone see any issues with that plan? I do NOT anticipate this bike being a show piece, I intend on riding it into the ground as my daily until it cant go anymore. I just don't want to create a safety issue.
My suggestion - since you have confirmed its all straight, I would either 1) weld a plate over it and keep riding or 2) cut out an appropriate size square and flush weld in an equal thickness plate, grind it smooth and paint it then ride the heck out of it!
I assume you got a salvage title since you bought it from the auction. Dealers aren't allowed any frame repairs. I would get someone to weld in a repair. I have seen the frame be replaced for that same damage. Good luck!
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Crash Bar Mount
