Premium Tour-Pak Hinges Install Tips
Seasoned HDF Member
Joined: Oct 2012
Posts: 24,287
Likes: 4,027
From: Western MN
Kudos to those who previously posted these tips for the install of H-D Premium Tour-Pak Hinges, helped me immensely!:
1. I used my new Dremel with a cutting wheel to smoothly grind down the rivets versus drilling them out. 16 rivets took about 1/2 hour to grind down and punch out going very slowly so as not to mess up!
2. Drilled out all 16 holes in the Tour-Pak lid and base with an 11/64 in. bit. Not mentioned in H-D instructions, but a must do for proper fitment.
3. Mounted new hinge assemblies to the Tour-Pak lid then attached hinge bottoms to Tour-Pak base. Opposite of what the H-D instructions say, but makes it a one man job. I held the lid steady by gripping my Premium Luggage Rack with my left hand while attaching the screws using a Torx driver with my right. Have everything needed for this task accessible right in the Tour-Pak if you attempt it without a helper! Still a tough job solo, but can be done.
4. Attached all fasteners and checked alignment then removed one screw at a time to apply Lock-Tite. I used Blue since I didn't have Red in my toolbox.
Here;s a tip I can add:
The lower part of the chrome hinge assemblies that attach to the Tour-Pak base were covered with clear plastic sheeting for protection from scratches. Very hard to see, almost missed it. Remove before assembly!
These hinges look way better than the stock assemblies! And I realized that, with two Torx drivers to undo the stock hinge pins, a thief could pop off the locked Tour-Pak lid in a couple of minutes! IMHO best $50 buck upgrade available to date.
1. I used my new Dremel with a cutting wheel to smoothly grind down the rivets versus drilling them out. 16 rivets took about 1/2 hour to grind down and punch out going very slowly so as not to mess up!
2. Drilled out all 16 holes in the Tour-Pak lid and base with an 11/64 in. bit. Not mentioned in H-D instructions, but a must do for proper fitment.
3. Mounted new hinge assemblies to the Tour-Pak lid then attached hinge bottoms to Tour-Pak base. Opposite of what the H-D instructions say, but makes it a one man job. I held the lid steady by gripping my Premium Luggage Rack with my left hand while attaching the screws using a Torx driver with my right. Have everything needed for this task accessible right in the Tour-Pak if you attempt it without a helper! Still a tough job solo, but can be done.
4. Attached all fasteners and checked alignment then removed one screw at a time to apply Lock-Tite. I used Blue since I didn't have Red in my toolbox.
Here;s a tip I can add:
The lower part of the chrome hinge assemblies that attach to the Tour-Pak base were covered with clear plastic sheeting for protection from scratches. Very hard to see, almost missed it. Remove before assembly!
These hinges look way better than the stock assemblies! And I realized that, with two Torx drivers to undo the stock hinge pins, a thief could pop off the locked Tour-Pak lid in a couple of minutes! IMHO best $50 buck upgrade available to date.
Looks like some OEM rivets under the seal.
Thanks -
Road Captain
Joined: May 2011
Posts: 565
Likes: 2
From: Palmyra Missouri
Ok I put latches and hinges on, I found that taking a putty knife and pushing the seal down on the lid to drill rivets worked well and kept the drill bit out of the seal and also someone holding the top down while I did it helps too.. Anywho I do like them, They are definitely heavier duty than stock.. Really not that hard, I made sure all the screws went in and got it all adjusted well and snugged then I pulled screws one at a time and put red loctite on. I too had to bend the locking hook to get it to line up and latch. I do wish the gaps on the latches were tighter but overall I like them so far... Oh yeah, Take your time drilling rivots with the 3/16th drill bit, and I used a 11/64" drill bit instead of 3/16th to enlarge screw hole cuz it allowed a tighter fit......
Cruiser
Joined: Dec 2008
Posts: 114
Likes: 0
From: Gettysburg, Pa
Great info. Had a friend notice mine last weekend, he looked back at his and we ended up at the dealer to buy him a pair. I am not taking credit though, these were the wife's doing. Very nice improvement from stock.
Tourer
Joined: Jun 2008
Posts: 411
Likes: 0
From: Livermore, CA
My tourpack should be in this week and I've been thinking about these hinges and latches. After reading this thread you've all convinced me to put them on. I'm assuming that it should be easier without the tourpack mounted. Thanks!
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