Left Side Cover Fix

[DGXSER]

I have a left side cover that has the typical broken locking tab issue. I do not have a lot of metal machining tools, or a welder. I am also a bit of a cheapazz, well documented I know. So I wanted a fix that I could make, but would be reliable and it had to be permanent. I had to be comfortable selling the bike with this fix in place.

After careful review, and thinking, I chose to replace the locking mechanism with a bracket. I do not consider the locking feature to be of any real value. So this is not a locking fix. I made the bracket and contemplated a couple options of bolting the side cover in place. I wanted the side cover to be easily removable on the side of the road, so the fix could not require tools to remove. Thought about a wing nut, but I also was concerned it would vibrate loose over miles of riding. This led me to using a latch pin. So I looked at putting the latch behind the side cover to keep the front of the cover clean, but this would make the pin difficult at best to get to. So the bolt was pu in the bracket and JB welded in place. I then painted the bracket to blend in with the frame.



Here it is from the underside.


Here is the bracket in place.


And here is the end product.


My only concern is how long the latch pin will last without rusting.

So here is one way to fix the side cover issue on the cheap.

[GLoweVA]

Love the ingenuity. Is the tab on the bottom of the cover 'naturally' that long?

If you're worried about rust, hit it with some rustoleum in a can.

Oh, and why 2 holes in the cover?

[DGXSER]

That is the factory length of the cover.

The two holes are from the method used by the prior owner to mount it. He had taken a thin piece of wood and use tie wraps to held the wood to the lock. He then used two wood screws through the cover into the wood block. It worked, but I did not like the look of it. I will probably fill the other hole and touch up the paint on the side cover at some time. The second hole was just enlarged for this modification.

[daveyg]

My SG has this identical issue! I will definitely copy/modify your design! Genius!

[Yahman]

I don't know if you have seen it yet, I posted in another thread, that I will have a repair kit ready in a couple of weeks. I ordered everything I need to make them yesterday. Cuda 69 has received his kit and will be installing it soon.

http://www.xs11.com/forum/showthread...079#post404079





Ride safe,
Larry

[jetmechmarty]

I don't know if you have seen it yet, I posted in another thread, that I will have a repair kit ready in a couple of weeks. I ordered everything I need to make them yesterday. Cuda 69 has received his kit and will be installing it soon.

http://www.xs11.com/forum/showthread...079#post404079





Ride safe,
Larry

I acquired a spare cover with that piece broken off. That will be the appropriate fix for me.

[DGXSER]

No doubt that is a nice piece and great finished product Larry. Great product for the price considering the material cost and the labor and tools to machine it.

As I stated, I wanted something a little less expensive, and something any person could make with just hand tools. Just an alternative solution.

[Yahman]

No doubt that is a nice piece and great finished product Larry. Great product for the price considering the material cost and the labor and tools to machine it.

As I stated, I wanted something a little less expensive, and something any person could make with just hand tools. Just an alternative solution.

I completely understand.

Larry