Deluxe Tour-pak Hinges
Tourer
Joined: Aug 2010
Posts: 451
Likes: 4
From: Oakland, Ca
1. Follow the directions and remove the stock hinge pins and lid before you start removing rivets.
2. Drilling the rivets works however I found that grinding the heads off with a Dremel is much easier then drilling around the lid seal. You're working on the opposite side away from the seal.
3. Use blue tape to cover the paint in any area you are working. One slip with the drill or dremel and you'll wish you did.
4. You will need to drill the holes out for the new screws since the screws are slightly bigger than the rivets.
5. You will only need extra hands when it comes time to bolt the lid back on. I managed without help.
2. Drilling the rivets works however I found that grinding the heads off with a Dremel is much easier then drilling around the lid seal. You're working on the opposite side away from the seal.
3. Use blue tape to cover the paint in any area you are working. One slip with the drill or dremel and you'll wish you did.
4. You will need to drill the holes out for the new screws since the screws are slightly bigger than the rivets.
5. You will only need extra hands when it comes time to bolt the lid back on. I managed without help.
I just did two in the past couple of weeks......the 1st was a "learning" experience. Follow the above and use a new drill bit........(not the self starting kind).
Outstanding HDF Member
Joined: Jun 2008
Posts: 2,134
Likes: 4
From: Third Coast, South Texas
If you don't have a grinder, use a putty knife or something else flat and thin to lay against the seal while drilling.
Outstanding HDF Member
Joined: Jun 2008
Posts: 2,134
Likes: 4
From: Third Coast, South Texas
btw, the instructions don't say a word about drilling the rivet holes to a larger size to accomodate the new screws, but you will need to. Just make sure you drill only the amount needed to fit the screws in
Road Warrior
Joined: May 2007
Posts: 1,277
Likes: 4
From: Austin, TX - Some call it heaven.
Yeah, it's an easy job. The only thing I would add is that if you have the Air Wing luggage rack with the light kit, make sure you disconnect the wire before you lift off the lid. Otherwise you'll be standing there feeling kinda foolish.
Don't ask me how I learned this.
Don't ask me how I learned this.
Elite HDF Member
Joined: Sep 2007
Posts: 4,928
Likes: 69
From: Near Myrtle Beach, SC
This is a must upgrade. The stock hinges look like crap.
Drilling or dremel, both work to get rid of the rivets. Always use a new, sharp drill bit. You need not put much pressure on the rivet when drilling because a good bit will cut through the curls of the rivet quickly. Once the rivets are out and the old hardware is removed, don't drill the holes any bigger than necessary for the new little fasteners. You can do this job yourself if you must, but it's not recommended. There is way too many opportunities to **** something up and create some bad scratching. My wife helped me once I was ready to put the new hinges on. She also helped me hold-back the rubber gasket when it was time to drill out those rivets that hide under that gasket...so as not to nick or damage the gasket.
Yes, 4 hands are recommended on this job, not mandatory, but recommended.
And yes, it is a sorry damn shame that a CVO model comes with the **** stock hinges. But CVOs come with a lot of stock **** that shouldn't be on a bike of that price class.
Drilling or dremel, both work to get rid of the rivets. Always use a new, sharp drill bit. You need not put much pressure on the rivet when drilling because a good bit will cut through the curls of the rivet quickly. Once the rivets are out and the old hardware is removed, don't drill the holes any bigger than necessary for the new little fasteners. You can do this job yourself if you must, but it's not recommended. There is way too many opportunities to **** something up and create some bad scratching. My wife helped me once I was ready to put the new hinges on. She also helped me hold-back the rubber gasket when it was time to drill out those rivets that hide under that gasket...so as not to nick or damage the gasket.
Yes, 4 hands are recommended on this job, not mandatory, but recommended.
And yes, it is a sorry damn shame that a CVO model comes with the **** stock hinges. But CVOs come with a lot of stock **** that shouldn't be on a bike of that price class.
Elite HDF Member
Joined: Jun 2006
Posts: 3,698
Likes: 11
From: Longview, Washington
$5 hinges on the Tourpak.
Even the salesmen are shaking their heads on that one!!!
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Outstanding HDF Member
Joined: Jun 2008
Posts: 2,134
Likes: 4
From: Third Coast, South Texas
Did the same thing today in Corpus Christi, 2011 CVO Ultra with these cheap lookin hinges.
Tourer
Joined: Apr 2010
Posts: 316
Likes: 0
From: Tulsa OK
Mine went ok. Still not finished completely, the hinge part is for the most part. I am also installing a TourPak Bra, so I haven't put the lid back on yet. Waiting for the Velcro to sit 24 hours, then will put it all back together.
I went and got 2 new drill bits. I had a 3/16", but it had seen better days. So I got a new one and a spare. Worked fine, and drill bit still looks like new. Tried the hinges real quick for fit/looks. No problems.
Sure does look lots better! Good $50 spent!
I went and got 2 new drill bits. I had a 3/16", but it had seen better days. So I got a new one and a spare. Worked fine, and drill bit still looks like new. Tried the hinges real quick for fit/looks. No problems.
Sure does look lots better! Good $50 spent!