Tour Pac hinge replacement gone wrong
Seasoned HDF Member
Joined: Jan 2011
Posts: 157,462
Likes: 57,017
From: Michigan 15 Minutes East Of Hell
20/20 Hind Sight .... or ... Optical Rectumitis !!!
Outstanding HDF Member
Joined: Dec 2007
Posts: 2,403
Likes: 20
From: Indy
A trick to removing the old rivets is to use a dremel tool to grind off the heads, on the inside, you get grind marks on the washers, but you replace them anyway.Then you can drill the holes out without spinning the rivets.
Road Master
Joined: Jan 2010
Posts: 881
Likes: 13
From: ONT
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!
http://www.sportrider.com/hands_on/1...ody/index.html
Outstanding HDF Member
Joined: Jun 2010
Posts: 3,356
Likes: 2
From: Las Vegas, NV
My dealership installs these hinges for a cuppla hundred bucks. At first I thought it was too much $$ and I would just do it myself. But after reading several threads about what can go wrong I am more inclined to let my dealer do the install.
Road Warrior
Joined: Apr 2007
Posts: 1,406
Likes: 5
From: Sunnyvale, Ca.
I'll do these all day long for $ 50.00 , it's not that hard with 2 people... as I posted: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!
Tourer
Joined: Apr 2010
Posts: 347
Likes: 3
From: Virginia
I also thought it was fairly easy but of course nerve racking drilling the tour pack. I did have help holding the tour pack while securing the new hinges. Can't imagine how hard it would be to do it by your self. And yes we have all done dumbs**t just most won't admit it....
Road Warrior
Joined: May 2008
Posts: 1,847
Likes: 6
From: FT Bragg NC
Can be done solo. My wife just sat in her chase chair and watched me do mine. For me it helped that my T/P is detachable. I did it while watching a football game.
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