BMW system case repair question

[Fly]

Well, two months later I finally have time and decided to begin the system case install.

Locks --- no problem (I think).

Problem --- when that certain BMW dealer shipped all the various parts and pieces they included them inside the case. Well thats fine...it saves on shipping. Note: I also bot the luggage rack. Well, what happened is during the process of packing and/or shipping, there is a small place were the plastic is broken right next the latching brackets, i.e., where the two steel hooks grab the lid when you close. The reason I found the problem is that after installing the locks and closing the lid I hear what I think are lose parts banging around. Not parts but plastic!

I didn't do it...I'm confident of that. Its too late to go back to the dealer. And its not a "fatal" flaw that will hamper operations.

Question: I'd like to repair the "hole" with something.

I first thought silicone but its too flexilble.

Maybe some type of epoxy?

I have some Yamabond 4 & 5 but I don't think they're appropriate here.

I need something that will dry "hard" and fill up the small (1/2" by 1/4") hole.

Your suggestions would be welcome.

[1MPH]

I used Bondo on my cases. Fixed up the holes real nice.

[DarthRider]

Fly -
JB "Quick" Weld should work but be sure and fill a "practice hole" first.
Regular JB Weld takes much longer to cure and will sag or run.

Ask a local Jap bike shop if they know anyone doing "plastic welding" repairs on crashed fairings, etc. That would be another, probably better option.

I assume the hole you mention is not "structural"? If so you might need something stronger or a replacement.

Dave

[Acacia]

Strutural adhesives on any of the 2600 different types of plastics that really weld them is a science - one needs to know the base chemistry and type.

Most adhesives will not really adhere chemically, but mechanically and that is never good on plastics. If you have access to a methyl methacrylate type - Loctite H3000 and its applicators - you are in luck for most ABS types. It is an industiral adhesive and not found in the corner store.

Epoxies can gap fill, some cyanoacrylates (super glues) - those with a thixatropic - or paste type, can join but not structurally, some plastics.

Can you get us some pics?

[Fly]

Well as it turns out, the lid will need to be replaced. There are cracks all around the hooks that allow the lid to be "grabbed" by the steel hooks.

I can't imagine I was that rough with them but both cases were very stiff and required considerable effort to close.

I ordered the replacement lid yesterday.

After seeing the damage, I will be very careful when closing these babies in the future!

Are the lids very difficult to change out?

[DJ Down Under]

Are the lids very difficult to change out?
No...a piece of cake..:icon_biggrin:

All you need is....Drill...pop rivets and rivet gun...and a few small nuts & bolts.

Do you need some pics?

DJ

[Fly]

I see that everything on the cases is rivoted.

I wonder (since I don't have a rivoting tool) if I could drill out the old rivots and bolt back together? Or should I rivet it back together?

DJ --- pics would be welcome.

Thoughts?

[DJ Down Under]

You can buy a rivet gun/tool for about $5-$10..they're very cheap....but...

The problem is that I couldn't find rivets long enough...(my last pic shows how long they need to be)

So I just drilled them out (on the lid side) and used small bolts with nylock nuts....Like shown in my pics..hope they help.

DJ

http://members.optusnet.com.au/~djp1/mypic2337.JPG

http://members.optusnet.com.au/~djp1/mypic2338.JPG

http://members.optusnet.com.au/~djp1/mypic2340.JPG

[Fly]

You can buy a rivet gun/tool for about $5-$10..they're very cheap....but...

The problem is that I couldn't find rivets long enough...(my last pic shows how long they need to be)

So I just drilled them out (on the lid side) and used small bolts with nylock nuts....Like shown in my pics..hope they help.

DJ



Thanks much.

[RandyRandy]

BMW likes to change about 30 bucks for the rivits. (sheesh!). They're just rivits, so after drilling, keep couple so you can size non-BMW replacements at the hardware store.

You may need to buy a 90-degree adapter for your power drill (I did). I couldn't drill the inner rivits without it.

Here's an earlier thread:
http://www.motorcyclistcafe.com/forums/showthread.php?t=109

[Promethean]

DJ,
Looks like this question comes up often....would you mind if we steal your images, description and put it in the FAQ?

[DJ Down Under]

Steal away..no probs...I have another hot little smiley to add.... http://members.optusnet.com.au/~djp1/mypic2342.gif

DJ

[Promethean]

Added ....and the smiley is now known as "flamin dj" heh! heh! :flamin_dj:



I have another hot little smiley to add....
DJ