Little Help with Tour Pack Hinge install
 

I've had the chrome Tour Pack hinges for so long I seem to have lost the install instructions. Can anybody tell me the size of drill bit needed?

Also, any other helpful hints would be good. I've heard some horror stories about installing these. That's why I've had them for so long.

Thanks!!

Did mine by myself but a helper would be nice so the lid does not get away from you.
Here are the instructions.
http://www.harley-davidson.com/en_US...ts/-J04544.pdf

Just take your time doing them. It's a good winter or rain day project. Not hard at all, just get somebody to hold the lid for you as needed.

Ditto. Smart money is to get someone to help hold the lid. Drilling out the rivets is a piece of cake. Take your time. They will look great and are one of the best upgrades for the tourpak.

It's always been amazing to me that the CVO bikes have the cheap-ass hinges on their tour paks. Sad.

Best bet is to expand hole incrementally until the screw goes through smoothly.

The instructions call for installing the hinge screws with red Loctite. I found it easier to install the screws dry, then come back after the installation and remove/reinstall the screws individually with the red loctite--less mess, at least for me.

Good luck with your project.

Carl

When I did mine in late 09 the supplied drill bit only drilled the hole to an interference fit with the fastener.
Not wanting the fastener to 'crack' the TP, I drilled it out one size larger so the fastener had a smidge of play around its OD.

Also when you drill the hole in the lid, use a kitchen spatula or a flat piece of plastic to hold the rubber gasket away from the drill bit, or the gasket will tear.

Another set of hands will help, although I did mine alone.

PS-- Blue locktight is what I used-- red not needed IMO.

You will need a 3/16" drill bit. Take the lid off and set aside and use a metallic object to hold back the gasket while drilling the rivets out.......this is the only part that I found tedious. Other than that, you simply loctite the screws and screw the hinges on. They look great once you're done and nobody can knock the pins out and steal your goodies :)
Good luck....it's an easy mod.

You'll definitely want a sharp drill bit though so that you can avoid melting the plastic with too much grinding.

I used a dremel with a grinder bit to remove the rivet heads, then the old hinges just popped off. Drilled the holes in the trunk body and lid out with a bit one size larger than the new bolts. Took a little over an hour all together.