Fork tube leak

08mastiff

08mastiff

Active Member
Well I got myself into a bit of a pinch. Disassembeld my front end to rebuild the forks with new seals and noticed immediately that the one bolt that connects the fender mount to the fork tube was broken. Apparently the genius before me decided to use red loctite on the thread. After disassembling the front end, draining the fluid and taking the whole unit apart I decided to try and drill out the old bolt and re-tap the thread. Yup you guessed it I made a pin size hole through the lower tube as I was getting the bolt out. :angry::angry:NOW WHAT ??!!!!

I went to the local Harley dealer inquiring for a solution and they suggested wrapping the new bolt for the bracket in teflon tape or using plumber's dope around the threads and assembling it as is. I wanted to know if they could plug weld it and then have it re-tapped. They didn't want to mess with it at all, especially since it's chrome (and probably cause it's not a Harley product). I go home and change the seals and fluids and put everything back together using the pipe dope on the threads. Did about fifty miles on it one day and everything looked good. Today did another 75 and you guessed it......it's starting to leak behind the fender mount bracket down the lower fork tube. No leaks any where else including the other tube. Everything was definitely installed correctly.

Looking for some suggestions before I take the plunge and buy a new lower fork tube. There has to be a way to plug weld it...NO? If need be does anyone have a lower for sale? Its the right side as you sit on the bike. Opposite the front brake.
 
nine lives

nine lives

Active Member
John, are you talking about the blind hole on the inside of your fork tube that the fender mount mounts to. I'm not at home to look at my bike.
 
nine lives

nine lives

Active Member
Ok, here is what I would do. I would first try to seal the bolt again using some teflon tape, wrap it thick. If that fails, I personally would tig weld it. It would be a tricky weld (no penetration) and use wet rags to minimize the damage to the chrome, but using a good tig welder, it's doable.
 
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Dezertrider37v

Dezertrider37v

Member
Man that sucks, I had to look at mine to see how much material is in there but i think that you might be able to drill and tap it for a time-sert (thread insert), not a heli-coil which is open ended. If you were to install the insert with jb weld to set it, it would not leak. Or you could take the fork leg back apart and jb weld it then retap it. I would say tig it but there is not too much room for error with the chrome.
 
08mastiff

08mastiff

Active Member
nine lives said:
John, are you talking about the blind hole on the inside of your fork tube that the fender mount mounts to. I'm not at home to look at my bike.
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Yeah, there is the fender mounting bracket that is attached to the inside of the fork leg with two allen head bolts. Its one of those bolts.

I was also thinking jb weld but afraid down the road it may not work because of all the vibration, at some point it may fail and start to leak again. Gonna have to try a welding shop somewhere I think. This way an expert can tell me if its do-able. I am willing to run the bracket with one bolt and just plug up the other.
 
RRRUFF

RRRUFF

Well-Known Member
Here is my 2 cents worth. If the hole is deep enough get a allen head set screw the shortest you can find. You may even cut down the top of the set screw and only leave enough allen head to screw it in the hole. Coat the threads of the set screw with JB Weld and maybe put a little down in the hole, screw it in untill it bottoms out and lightly tighten it. It maybe best to disassemble the fork so if any JB weld goes through the hole into the fork tube you can imediately clean it up. Allow the JB weld to cure then re-assemble the fork. Now use a shorter fender bracket bolt that won't bottom out against the set screw. Now all of this is assuming the hole is deep enough and you will have enough threads for the fender bracket bolt to torque properly, use blue 242 locktite on the bolt. Should be good to go. Hope this helps!
 
pknowles

pknowles

RETIRED
RRRUFF said:
Here is my 2 cents worth. If the hole is deep enough get a allen head set screw the shortest you can find. You may even cut down the top of the set screw and only leave enough allen head to screw it in the hole. Coat the threads of the set screw with JB Weld and maybe put a little down in the hole, screw it in untill it bottoms out and lightly tighten it. It maybe best to disassemble the fork so if any JB weld goes through the hole into the fork tube you can imediately clean it up. Allow the JB weld to cure then re-assemble the fork. Now use a shorter fender bracket bolt that won't bottom out against the set screw. Now all of this is assuming the hole is deep enough and you will have enough threads for the fender bracket bolt to torque properly, use blue 242 locktite on the bolt. Should be good to go. Hope this helps!
Click to expand...
Sounds like you put some thouht into this one:2thumbs:
 
08mastiff

08mastiff

Active Member
RRRuff that does sound like a good idea. My only concern is whether or not the JB weld will last with all the vibration running through it over time. This is an issue I don't want to revisit again. Unfortunately I cant get to it until Monday because of my work schedule. I am going to disassemble it again and take it to a welding shop and get their expert advice. I rather plug weld it for good and possibly tack weld the bracket through the screw hole onto the fork. Then I will put the other bracket screw in the other hole and hopefully put this issue to bed. Even though I just replaced the gaskets and seals last week, I dont think I want to reuse them again and risk a leak, especially after pounding them in. That's why I want to make sure my next attempt is my final attempt with no future worries or having to buy seals until the next 5,000 miles. Thanks for all the input and great ideas.:2thumbs:
 
RRRUFF

RRRUFF

Well-Known Member
No problem just an idea. I was thinking the JB weld would act like a thread sealant. Certainly welding would be a permanant solution if you can do that. And yes I would change the seals again, won't be a better time. Hope you get her fixed.
 
08mastiff

08mastiff

Active Member
RRRuff I took your advise on the J B Weld. What I ended up doing was place the J B Weld in the lower fork tube hole, placed the fender bracket over it, and screwed it on very tight. The total length of the screw is only 1/4 inch so trying your method would not have given me the clearance with a second screw over it. Naturally some of the J B weld leaked into the tube but I wiped it out immediately. I gave it 24 hours to harden just to be on the safe side and put the front end back together. Today I went out for a 150 miles or so and everything seems to be leak free. That bracket is staying on for good.....Hopefully. Thanks for the recommendation. :2thumbs::2thumbs:
 
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