Inner fairing windshield insert fix.

[Admiral Akbar]

On the EGC, I had a windshield screw pull out of the inner fairing.. (Used bike  )

Anyway to fix... I pulled the insert and cleaned it up.. There was a black plastic ring in the insert groove from the fairing so I removed it and cleaned it up..



I cleaned the hole in the inner fairing with break clean on a Q tip then dabbed JB weld (any quality epoxy will do) into the hole..



I slid the insert back in between the fairing and screwed in a long screw then dabbed the insert with more epoxy.



Using a big pair of channel-locks, a small wood block and rag, I squished the insert on the screw, back into it's place. (sorry no pic, not enough hands) until the insert bottomed and epoxy oozed out around the insert. I let it set for a minute or 2 then removed the screw.. You could use a release agent on the screw and just leave it in place if desired. I was to lazy to dig some up.



Notice there was enough pressure to force the epoxy out the crack in the boss..
After drying for over night.. put it back together..

Now it's Mayors turn to come up with something..

Max

[Buglet]

   Harley sells a replacement insert that screws in. They work great.

[truck]

By fixing the insert you also fixed the crack.

[HV]

We use the Harley repair inserts all the time... real good fix ..threads in and makes the insert damn near impossible to strip out again

[Admiral Akbar]

If you look at the boss, It's split.. You can see a faint line where the epoxy oozed out..  Would they still work? 

FWIW, the fix took less time than do than it takes to suit up and warm the bike up.. Of course is you are looking for a reason to hang out at the dealer for a while.. or you are a dealer. in that case you walk over to the parts dept and pick up the kit..


I was thinking about drilling the hole all the way through the making a semi-fancy googaw out of stainless but I suspect that the next time it goes it will be taking the boss with it..

added

Max

[HV]

If you look at the boss, It's split.. You can see a faint line where the epoxy oozed out..  Would they still work? 

FWIW, the fix took less time than do than it takes to suit up and warm the bike up.. Of course is you are looking for a reason to hang out at the dealer for a while.. or you are a dealer. in that case you walk over to the parts dept and pick up the kit..


I was thinking about drilling the hole all the way through the making a semi-fancy googaw out of stainless but I suspect that the next time it goes it will be taking the boss with it..

added

Max

Yes Max I do them all the time that are cracked... to installl... find a small bolt and nut... thread it in to the insert ( split end facing in to the fairing to cut new threads )  use the bolt head to thread the new insert in... back off the lock nut and remove the bolt .... after the crack has no bearing because its the course threads on the new insert that hold it in...not the fit in the faring hole

[Admiral Akbar]

I'm having trouble visualizing it.. Seems to me that the threading the boss would only split it more..
I guess that's an excuse for me to go down and hang out at the dealer and see what the kit looks like.. 

Max

[road-dawgs1]

16585-96 threaded insert
stock on the left in the photo, repair insert on the right

[attachment removed after 60 days by system]

[road-dawgs1]

Although it looks like you would use the slot to screw it in with a screwdriver, you don't.  That is the other end.  You can use a screw and some nuts to thread it in.


[attachment removed after 60 days by system]

[05FLHTC]

I JB welded one of mine about 2 yrs ago, been fine ever since

[smoserx1]

I'm having trouble visualizing it.. Seems to me that the threading the boss would only split it more..

One of them did on mine when I use them.  I replaced all three at one time.  The instructions say use a 0.330 inch drill.  I didn't have that (I forget exactly what I used, but It was the next smaller drill size) and that one split the plastic.  For the other two I used the next larger size and no problem.  I guess if you do lots of them you learn.  It is a moot point because not too long after that the entire plastic failed on both sides where the vertical inner fairing brackets mount and I just went ahead and replaced the whole inner fairing.  Nice Saturday half day job.

I think your repair method is pretty good.  Thanks for sharing.

[Billy]

been there done that, the epoxy held for awhile but repeated removal & installation it failed, put the inserts in and no problems since. can you say 20 in/lbs?   

[crazybastid83]

To use the HD kit you drill out the boss with an 8mm (or 5/16) drill bit.

[fleetmechanic]

When using the repair insert we also tap threads in the plastic with a 3/8-16 tap.  Avoids splitting the hole.

[Billy]

To use the HD kit you drill out the boss with an 8mm (or 5/16) drill bit.

...and when you go to drill it, wrap some electrical tape around the bit to act as a depth stop, if you don't and the drill bit grabs the soft plastic it will be through to the other side faster than you can say "oh "Potty mouth"!"

[smoserx1]

The instructions (-J01733) say "Drill out the bore of the boss using a 0.330 in. (8 mm)
drill."

Well, 8mm is not 0.330; it is 0.315.  That is a big difference. 

I did not check this math before I began, and relied on the 0.330 specification as being valid.  Since I only have fractional drill bits I used a 21/64, since this would be 0.328, and was the closest I had without going over.  The right side worked fine, the center one split.  On the left one I used an 11/32 inch bit (0.344) and that worked ok.  Since 8mm (or 5/16) both would drill an even smaller hole than anything I used, it looks like those sizes would have split even worse when I attempted to install the insert.

I got a feeling that the center boss may have already been split.  Like I said it wasn't too long afterward the plastic totally failed where both the mounting brackets attached.

[mayor]

Now it's Mayors turn to come up with something..

Max

yep, thanks for the pics.  should help with the process.    

[nemick]

I replaced one of mine last week with one of the HD inserts. It didn't come with any instructions, so I just screwed it in using a bolt and locknut. Worked great and didn't crack the boss.

[Deye76]

"Harley sells a replacement insert that screws in. They work great."


 

[klammer76]

I replaced one of mine last week with one of the HD inserts. It didn't come with any instructions, so I just screwed it in using a bolt and locknut. Worked great and didn't crack the boss.

Same here, no instructions, just screwed it in, slotted side facing in. No problem. Maybe I just got lucky?

[Admiral Akbar]

been there done that, the epoxy held for awhile but repeated removal & installation it failed, put the inserts in and no problems since. can you say 20 in/lbs?   

One thing I forgot to mention is that if you run bolt all the way into the insert, you can over fill the hole slightly and get it to ooze out around the insert, this helps to ensure that there aren't any voids in the epoxy giving a good grip.. Cleanliness and making sure to remove the piece of plastic that pulls out with the insert are also important or you won't have a good bond.

Max

[Ridetard]

Here's my "shade tree" cure.

Find a metal washer with the correct size center the the insert will fit into.  JB weld the washer to the inside on the fairing at the insert location..

You will never have an issue again.

[Glide-Rider]

Max,
I have 02 FLHT and the lower bolt and insert just spin.  It is the lower left one that goes thru the fairing skirt.  I have tried to apply pressure by pulling on the outer fairing as I am trying to remove bolt.  Bolt and brass fitting just spin.  Any suggestions??

[Admiral Akbar]

Max,
I have 02 FLHT and the lower bolt and insert just spin.  It is the lower left one that goes thru the fairing skirt.  I have tried to apply pressure by pulling on the outer fairing as I am trying to remove bolt.  Bolt and brass fitting just spin.  Any suggestions??

Seems to me that once the insert has popped loose.. You should be able to to pull the fairing off leaving the insert/screw hanging on the inner fairing.. I'm not expert here as I've not even pulled the fairing off and am not sure as to which screw you are having a problem with... I'd probably remove all the fairing screws except the offender.. Maybe the running lamps then see if you can gently pry apart the remaining stuck spot (maybe with nylon panel removers) while turning the screw.. Insert should pull out.. Then unscrew the insert from the screw. 

Max

[glens]

I'd take a large soldering iron and heat the screw up 'til the insert gets warm enough to soften the plastic.  Either pull it on out or work it in and let it cool; maybe it'll hold the plastic long enough to let you back the screw out.