Broken Fairing Bracket Repairs
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
This is exactly the procedure I took in '08 and wrote-up here, except my hardware doesn't look as elegant as the OP's and I made no attempt to make it look good, which is obvious. I just used pieces of metal I found in my storage bin of junk, and they've held for almost three years. The good news is if they break I'll just install new pieces.
I haven't found a fix for the horizontal brackets, however, but the new design looks like they'll hold better. I've had a new-design left-side horizontal bracket installed for about a year and it has held, and just replaced the right side with a new-design bracket. I've had heavier speakers installed for years (1.75# Hogtunes vs. 12-oz. stock), but just installed some 2.5# Hertz 6˝" speakers, which is a step in the right direction for sound quality but the wrong direction for mitigating the stress on the brackets. We'll see how they fare.
If you'll look at the photo, I've thought about installing a second fabricated horizontal bracket on each side between the two arrows, which should add some structural sturdiness. Does anyone have any thoughts on this idea? BTW, the vertical bracket (right-side) seen in the photo has never broken, and when I fixed the left side I fortified this one as shown.
It might look something like this photoshopped image:
I haven't found a fix for the horizontal brackets, however, but the new design looks like they'll hold better. I've had a new-design left-side horizontal bracket installed for about a year and it has held, and just replaced the right side with a new-design bracket. I've had heavier speakers installed for years (1.75# Hogtunes vs. 12-oz. stock), but just installed some 2.5# Hertz 6˝" speakers, which is a step in the right direction for sound quality but the wrong direction for mitigating the stress on the brackets. We'll see how they fare.
If you'll look at the photo, I've thought about installing a second fabricated horizontal bracket on each side between the two arrows, which should add some structural sturdiness. Does anyone have any thoughts on this idea? BTW, the vertical bracket (right-side) seen in the photo has never broken, and when I fixed the left side I fortified this one as shown.
It might look something like this photoshopped image:
Last edited by iclick; Jul 21, 2011 at 01:13 PM.
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
Nobody has an opinion on the extra-bracket idea? I think I'm going to try it, as I can't think of a downside to it, and more structural strength from another angle can only help the stock bracket do its job and stay intact, or so it would seem.
Outstanding HDF Member
Joined: Jan 2010
Posts: 2,916
Likes: 31
From: earth
https://www.hdforums.com/forum/touri...-brackets.html
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
I think its a fantastic idea, in fact I took it to a whole nuther redonkulous level with mine. I'm all about the added structural support, needles to say I haven't had any further fairing mount bracket cracking issues.
https://www.hdforums.com/forum/touri...-brackets.html
https://www.hdforums.com/forum/touri...-brackets.html
I don't know how I missed your earlier thread, but I think you should build a kit for resale. It might not hurt to make-up a few kits and sell them on Ebay, just to get a feel for whatever market is out there. Anyway, what happened to the instruction set you promised in the old thread?
Last edited by iclick; Jul 22, 2011 at 01:40 PM.
Outstanding HDF Member
Joined: Jan 2010
Posts: 2,916
Likes: 31
From: earth
All common hand tools. More patients than skill. I did fall short with the instructions because that bracket incorporated my custom mirror mounts also, that would make it different without the mirror mounts. Also working through the process it was obvious to me it has to be built the way I did it, measuring and cutting and drilling as you go to make it fit. To lay out a precisely measured blueprint to construct from scratch would likely not bolt up properlyconsidering the subtle diferences in the way the fairing and brackets are aligned from bike to bike. If you want to work this project I can send you some additional pictures, and general guidance how I approached this.
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Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
All common hand tools. More patients than skill. I did fall short with the instructions because that bracket incorporated my custom mirror mounts also, that would make it different without the mirror mounts. Also working through the process it was obvious to me it has to be built the way I did it, measuring and cutting and drilling as you go to make it fit. To lay out a precisely measured blueprint to construct from scratch would likely not bolt up properlyconsidering the subtle diferences in the way the fairing and brackets are aligned from bike to bike. If you want to work this project I can send you some additional pictures, and general guidance how I approached this.
Anyway, I just bought some ˝" x 1/8"-thick iron strips today. Either way I will need to extend the top vertical bracket bolt a bit to accommodate the extra thickness of the fabricated bracket and probably a washer. Since my parts manual doesn't show the damn thing I'll have to find out what size it is at the HD shop tomorrow. Anyone know what size and pitch that bolt is? I think the bolts on the speakers (Biketronics) are long enough for the extra bracket thickness, but I have doubts about that stock bolt.
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