Broken Mount on Electrical/Side Cover

[claw]

It may not be perfect, but it doesn't show while on the bike, and it beats buying a new cover and paying someone a couple of hundred bucks to paint it. I tried epoxy first, but it came apart the first time I took the cover back off. I've had the cover off a few times since this repair, and its still holding strong. Maybe this will save someone some $$$$.

Washer has 1/2" dia. ID to accept the gromet.

 

[Little-Boo]

If you are looking for one, I have one for the right side that I bought on E-bay. It is already painted Black Cherry or cherry black same color as yours. The part No is BD2803-Right Hand. Its for a 2006 Mastiff, check your part no it may be the same. I'll sell it to you for 135 Plus shipping which is what I paid painted and all. New Never used or installed.

Carlos

 

[Nukeranger]

I don't know what possessed me to use JB Weld but here is what mine look like and have been like this for at least 6 months

One of them I used Loctite super glue but went back over it to reinforce it with JB Weld.

I plan on a small amount (very little) sanding after I show Big B Jeffers and then get Big B Jeffers to color match it. But like you said, you can't see it once the seat is on!

 

[BigDogBro1]

Before I installed the side cover bolt upgrade I did this...

Purchased four stainless steel hex socket head cap screws from the hardware store.

Drilled a .040" hole through both sidewalls to accept a solid wire (stainless safety wire).

Replaced the four original Bigdog sidecover bolts with the newly modified ones.

Just tighten enough the take up any looseness in the cover but don't overtighten which causes the plastic cover to split around the grommet.

Run the safety wire between the front two screws and secure ends of wire.

Run the safety wire between the rear two screws and secure ends of wire.

This will allow the screws to securely hold the covers without excessive expansion nut pressure on the cover.

Cheers!