slowrower
2007 Mastiff
Thought I would post some pics on how to prevent your battery/electrical covers from breaking. My first set broke at about 900 miles, the replacements include new hardware and pins look as if they may prevent the tabs from breaking but I am not taking any chances and I do not want to wait another six weeks for new ones.
Here is the replacement - paint matched perfectly
BDM supplies new pins and grommets along with instructions to ream out the holes on your bike
The new gromets are much softer and easier to install. They should help a bunch however, the material is still thin and somewhat fragile so its time to improve things a bit.
I will reinforce the cover and area where the covers attach to the bike using Kevlar. Kevlar works great for reinforcing structural areas and will hopefully prevent the area around the mounting from breaking again.
Time to test fit and cut the Kevlar tape. This stuff will not cut with scissors, so be prepared to go through 3 or 4 exacto blades. If you tape over where you want to cut you will get clean lines.
This is plenty of material for this tab
Using a dremmel tool I cleaned up the area where the Kevlar will be laid down and roughed it up for better adhesion
The third tan roughed up.. Notice the green colored tape, I taped the entire painted side to prevent scratched, marks ..etc.
After mixing the resin with the hardner using a small cheap throw-away brush I brushed on the resin then applied the Kevlar material. Keeping the brush wet with epoxy work the cloth into the bends and brush out any air that may be under the cloth.
The cover is now reinforced, when it hardens I wil cut off the excess, drill out the holes and then mount them on the dog.
This is what I use, it comes with pumps that squirt the proper ratio of resin to hardener so no guessing or measuring. You can get this a your marine supply store. For Kevlar go on line and do a search for Kevlar Tape. lots of places sell this, get 4" wide fine 6k or better weave.
Using a 3/8" drill bit you ream out the four holes to accept the new pins (bright aluminum in photos). Keep in mind, you use the original lower grommets - the kit is for the upper mounts (frame mounts).
All done!! time to clean up my grubby paw prints. This cover should last well beyond my ownership.
Here is the replacement - paint matched perfectly
BDM supplies new pins and grommets along with instructions to ream out the holes on your bike
The new gromets are much softer and easier to install. They should help a bunch however, the material is still thin and somewhat fragile so its time to improve things a bit.
I will reinforce the cover and area where the covers attach to the bike using Kevlar. Kevlar works great for reinforcing structural areas and will hopefully prevent the area around the mounting from breaking again.
Time to test fit and cut the Kevlar tape. This stuff will not cut with scissors, so be prepared to go through 3 or 4 exacto blades. If you tape over where you want to cut you will get clean lines.
This is plenty of material for this tab
Using a dremmel tool I cleaned up the area where the Kevlar will be laid down and roughed it up for better adhesion
The third tan roughed up.. Notice the green colored tape, I taped the entire painted side to prevent scratched, marks ..etc.
After mixing the resin with the hardner using a small cheap throw-away brush I brushed on the resin then applied the Kevlar material. Keeping the brush wet with epoxy work the cloth into the bends and brush out any air that may be under the cloth.
The cover is now reinforced, when it hardens I wil cut off the excess, drill out the holes and then mount them on the dog.
This is what I use, it comes with pumps that squirt the proper ratio of resin to hardener so no guessing or measuring. You can get this a your marine supply store. For Kevlar go on line and do a search for Kevlar Tape. lots of places sell this, get 4" wide fine 6k or better weave.
Using a 3/8" drill bit you ream out the four holes to accept the new pins (bright aluminum in photos). Keep in mind, you use the original lower grommets - the kit is for the upper mounts (frame mounts).
All done!! time to clean up my grubby paw prints. This cover should last well beyond my ownership.
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