2000 Electra Glide Classic.
I loosened fairing bolts to install new windshield. When putting fairing back together, I apparently tightened the bolt by the left side speaker too much. I heard a pop then realized the plastic of the bolt hole was damaged just enough for the bolt to go through so now I can't tighten fairing together properly. Tried a washer but was too big to fit in bolt hole. What can I do? No cracks or anything, just plastic that holds bolt head popped off fairing. This sucks!
any and all advice will be greatly appreciated!
Thanks

 

Can you post a pic of the damage?

 

HD sells a brass insert kit that fixes that, its not to expensive. Sounds like you stripped the brass insert and its turning in the hole and not tightening.

 

maybe buy one of those trim strips that go across the front taking in all three bolts. they make them plain or with all kinds of designs and colors, some even have lights in them. fast aire .com got them and all kinds of windshleids to chose from as do many other vendors out there.

 

Some of you aren't understanding. .....this is the inner fairing bolt by the left speaker. Windshield bolts and holes and fasteners are fine. The plastic on the inner fairing the keeps the bolt head in place snapped allowing for the bolt when tightened to go through inner fairing causing a gap between inner and outer fairing. Like I said, didn't crack or break anything else. Just small circular plastic piece molded into inner fairing bolt hole to hold bolt head. I'll take some pics in a little bit to show location, but can't really see damage. Just can't put fairing together properly like this.

 

cut some steel and epoxy it in place.

 

Sounds like you need a new inner fairing then. I really don't understand what you are describing. Pics help so we can understand. From what you are describing one of the bolt (inserts) on the INNER fairing has let go. IF this is not one of the windshield fairing brass inserts, then what is It? I have never heard of one of the speaker bracket bolt threads gone bad on this forum. If that is the case, as I stated earlier, you might need a new inner fairing which can be had off flea bay for round 100 bucks or so, OR put a helicoil in it, just sayin. We need more info or pics instead of you insisting this is what has happened. I just RE READ your last statement, sounds like one of the permanent bolts by the speaker has let go. I do not know of a repair for that except a different inner fairing. Sorry bout the ramble. Lemme know if I am wrong about what I have described.

 

Do you mean the ones right below the speakers on an angle?

 

I believe the holes you are talking about are recessed in, so it would be hard to use a bigger washer because it will not fit into the bolt hole itself, if and its a big if you were to do something like that you would need a really long screw then use the washer on the outside of the recessed hole, wow I hope this makes sense. And I am not sure that would even work. Only other thing is if you don't want to replace it, I would try to epoxy the hole from the inside of the inner fairing then drill it out to size. Not sure if this helps.

 

By inner fairing, I mean when you sit on the bike, you can see the bolt. There's one on each side of the fairing by the speaker, not holding the speaker. Take away the 3 windshield bolts. Then you have four fairing bolts. 2 that are somewhat underneath the fairing by the forks. 2 that are near the speakers. It's one of the bolts that secures the inner fairing to the outer fairing. I apologize if I'm using the wrong terminology, but I've always called the side of the fairing you look at while riding which has your gauges and radio in it the inner fairing. Will post pics when I get home and take some. Just needed input in case I needed to pick something up on way home.
And I do thank everyone who has posted trying to help.