I knew the mounting tabs were broken

[wes0778]

but I didn't realize they were still caught up inside the right lower. As some know the PO fell down and skinned up the the whole right side of my bike before I bought it. I knew this going in, so no big deal. Not sure what happened to the left lower, but the front two button head bolts are all that is holding both lowers on.

Yesterday I decided to install my new wind deflectors that mount on the crash bars. Well the PO had just straightened the right one even though the top mounting hole was torn. The deflector did not look right, so I decided to install the new (to me) crash bar that has been on my shelf for too long. When I pulled the lower, the two broken mounting tabs fell out, Yay!!!

The PO had tried to glue them back on with some type of hard white stuff. It didn't "weld" to the ABS. As the tabs edges would not sit flat down on the mating surface I didn't think the ABS glue would hold them, so I decided on reinforcement, ABS glue and epoxy. Not the prettiest repair, cause there are screw heads showing, but I suspect the tabs will not come off anytime soon!

I found some sheet metal screws(they don't all match, but they don't show either) and installed them at 90 degree angles, then filled the cavities with (two part) epoxy. The epoxy may/may not stick to the ABS, but it WILL stick to the metal screws!

[Snaggletooth]

The two part epoxy will hold like stone if you got it clean. I rebuilt, repaired or replaced about every mounting tab on my bike with the two part and pieces of ABS plastic I salvaged from work. Been a couple of years and no cracking or breaks since.

 

Clean, sand the edges, wipe with alcohol and epoxy. Done deal.

[Yammer Dan]

Looks like they ain't going anywhere for a while.

[bull463]

When mine broke. I put a spring on thr rear cylinder where the esahust is and a small hole in whats left of the tab. I made sure the spring has some tension on it it has worked great for 2 yrs now .