Found both my vertical fairing brackets broke today. I am going to use some 11/2'' X 1/8''
aluminum angle to replace the broken ends. What I'm wondering is should I use some rubber between the pieces for cushion? Has anyone tried this? I've replaced 1 horizontal
bracket , and welded one.This is my first time on the vertical ones.These brackets are
a pain in the butt.

 

I'm no metallurgist but I would think aluminum brackets would be more succeptable to cracking. IDK

 

Just changed my inner fairing on my 07 & BOTH tabs were broken!! I was Pissed!! $45.00 each!! HD knows this is a problem because, new replacements are a new design...are a little more "boxed" @ the mounting tabs than the old ones. Old design can't hold up to extra "shake" of the 96"? I don't know but, I had been wondering why my F'in fairing shook so much!! $90.00 I don't think I should have had to spend!

 

I did a similar repair like you are talking about. After the repair and several thousand miles the fairing tab where the brackets mount broke. I used fiberglass to repair. I would suggest some form of shock absorber material to try to keep that from happening. It was an 05 FLHTI. Harley does a great job of fixing an on going problem, NOT!

 

Are ya'll talking about the ones that run from the side of the radio to the bottom of the speaker? If so, one of mine broke last week, and replaced both for less than 20 bux from my local stealer. Cheapest thing I've bought from them.

 

For the tabs breaking off the main brackets at the top I just rewelded mine and built up a good weld on the inside of the tabs where they were broke. Also if you look at the brackets the tabs are folded over so the only part connecting them to the bracket is where they are folded over.. There is a gap at the bottom of the tab. I welded that on both sides also.. Seems to be fine for now.. I should have taken some pics but once you get your apart you will see what I mean.. Since the tabs are just folded over they couldnt be attached to the lower side and H/D should have welded them in the first place. I did at certain speeds notice a little more vibration but i may have to reroute some stuff behind the fairing ?.. At least at an idle it doesnt try to shake off the bike now .. My side brackets to the speakers are fine..

 

There was a company that made a replacement bracket with a rubber bushing built into it to absorb the vibration. My line of thinking I would rather have the bracket brake then the fairing so the op post of the rubber bushing is right online imho. Problem is I can't find the company, anyone know the company?

 

When I tore mine apart to paint the inner, I found that 3 of the supports were broken. Both speaker brackets and 1 vertical. No wonder it was clanking around so much! I bought the new "upgraded" horizontal ones and fabricated a fix out of stainless for the verticals with small welded gussets. The new speaker brackets are made way better and hopefully will last for the life of the bike now. I was so surprised to see how cheesy they were after seeing the quality of everything else I had my hands on while disassembling the bike. The verticals are thicker steel but the way they're made is stupid IMO. Only folded over? C'mon! Something that takes that kind of abuse should have at least been welded along the one edge that almost touches. HD sure knows how to make $$$.

 

The updated version of the HD fairing brackets are a bit more robust. I had them replaced under warranty last year. Time will tell if they solve the problem?
Prior to that I fab'd my own end piece once, as you are. It held up perfect.
Check J & P Cycles. I know Iv'e seen the end piece with rubber bumper in their catalogue. Not cheap though (around $25) which would put you close on price to HD's upgraded version.
One thing I've noticed with the upgraded brackets (I have all 4), a bit more vibration in the mirrors & wind deflectors. I firmly believe that's the real reason they never changed their design until now. The old design had perfect harmonics, at least until it failed.

 

I fixed them on my Street glide with some steel angle, pre drilled and used some nuts and bolts. They have been good for a year now. I took a picture of it back when I did it. I just used some random screws I had sitting around. Its not seen back there anyways.