Tour Pac hinge replacement gone wrong
Road Warrior
Joined: Apr 2007
Posts: 1,406
Likes: 5
From: Sunnyvale, Ca.
Great Pictures and write up:
http://www.hdtalking.com/harley_davi...hinge_kit.html
It was pretty much a caveman level project. Like I said, instructions were very good for a change. A helper to hold things steady while you tighten the screws would speed things up but is not absolutely necessary.
Two tips I can think of:
1. Instructions say to drill out the old hinge rivets with a 3/16 inch drill bit. I decided to start smaller and work up to that size bit if needed. Got the rivets out with a 1/8 inch bit just fine. Only later did I discover that the new screws (16 of them total) wouldn't fit through the 1/8 inch hole that remained behind so I had to go back and redrill the holes with the 3/16 inch bit anyway. Save yourself some time and use the 3/16 inch bit right from the start.
2. I used one of the old hinges to compress the tour pak lid gasket while drilling out the rivets hiding behind this gasket. Still managed to slightly crease the gasket with the drill but nothing major. This is where an extra set of hands would also have been really nice.
Oh, and be careful after the rivets and backing plates pop off - those dudes are HOT from the drilling!
Road Warrior
Joined: Jun 2009
Posts: 1,687
Likes: 9
From: SoCal & West TN
Supporter
Joined: Aug 2008
Posts: 5,189
Likes: 16
From: N.E. Wisconsin
try a couple of layers of duct tape here an there (only for a backup) just take your sweet time so your not nervous.
Last edited by drukanfu; Jan 10, 2012 at 05:31 PM.
Road Warrior
Joined: Oct 2010
Posts: 1,597
Likes: 1
From: Frederick, CO
I installed these the day i got my bike. I didnt have any issues while installing. but i did run the drill bit into the side of my finger while holding back the lid gasket. worth it if all goes right. They are an nice addition to the tourpak. but painful and expensive if something goes wrong.
Supporter
Joined: Aug 2008
Posts: 5,189
Likes: 16
From: N.E. Wisconsin
Well I was replacing the hinges on my tour pac with the deluxe ones.I had the hinges mounted and was connecting the lid cable at the lid.Without supporting(cable on post) the lid I reached down into the pac to grab the screw and next thing I know,the phucking cable slips off and the lid flips over and CRACK!
Now there is a 2 1/2" long crack from the front hinge mount.
I bought some black ABS cement and placed some in the crack.I let that dry overnight.The next day I used two pieces of fiberglass mesh tape used for drywall.I placed the tape on the inside covering the crack and applied 2 layers of cement.Also made an aluminum support to replace the two metel washers.Seems to be sturdy.From the outside it looks like a scratch.
Got a qoute from Lake Shore......$517 for a color matched bottom with free shipping.Not sure what I'm going to do.
Add this to the dumbshit list!
Now there is a 2 1/2" long crack from the front hinge mount.
I bought some black ABS cement and placed some in the crack.I let that dry overnight.The next day I used two pieces of fiberglass mesh tape used for drywall.I placed the tape on the inside covering the crack and applied 2 layers of cement.Also made an aluminum support to replace the two metel washers.Seems to be sturdy.From the outside it looks like a scratch.
Got a qoute from Lake Shore......$517 for a color matched bottom with free shipping.Not sure what I'm going to do.
Add this to the dumbshit list!
Tourer
Joined: Jul 2010
Posts: 381
Likes: 1
From: East Coast
The premium hinges give the lid a much more solid feel than the originals and look SOOO much better. Despite being nervous as hell that I'd mess it up, things went without a hitch. I had a buddy to hold things for me while drilling and securing. I don't think I'd do another one without that extra pair of hands.
Come on man! Get the 'ol lady to help. She can even polish the bike when you are finished. It'll make her feel "involved".
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Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
Two tips I can think of:
Instructions say to drill out the old hinge rivets with a 3/16 inch drill bit. I decided to start smaller and work up to that size bit if needed. Got the rivets out with a 1/8 inch bit just fine. Only later did I discover that the new screws (16 of them total) wouldn't fit through the 1/8 inch hole that remained behind so I had to go back and redrill the holes with the 3/16 inch bit anyway. Save yourself some time and use the 3/16 inch bit right from the start.
Make sure you have sharp drills on hand for the rivets.