Side panel "Bosses" (studs)


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Maddogg
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Side panel "Bosses" (studs)

Postby Maddogg » Fri Oct 11, 2013 1:05 pm



Ok guys, here goes. Side panel stud, (Boss), is broken off. I ordered stud balls from online and will be replacing broken Boss with stud ball. I am using JB weld for plastics as the side panels are ABS plastic. I am taking pics of the process and will post if I can figure out how to get them on here. You may have to cut the length of the stud ball as all the Boss's are different lengths depending on where they mount on the panel. Thought about using an Epoxy, but there are only about 1,000 different ones out there, and it is very confusing trying to find the right one to bond plastic. Will let you know how it turns out. If anyone has any great ideas on how to do this easier or better, I am all ears. Cant just use ABS glue if you don't have the Boss.



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Re: Side panel "Bosses" (studs)

Postby daveinozbikes » Fri Oct 18, 2013 8:17 am

Use Araldite slow setting(24 hours) ...they used it for building aircraft. Used it on my side cover a year ago and no problems. :)

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Ol' Man
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Re: Side panel "Bosses" (studs)

Postby Ol' Man » Fri Oct 18, 2013 8:49 am

daveinozbikes wrote:Use Araldite slow setting(24 hours) ...they used it for building aircraft. Used it on my side cover a year ago and no problems. :)

Thanks. I have used epoxy and JB weld with no success. It may be just me. :(
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Re: Side panel "Bosses" (studs)

Postby RBGERSON » Fri Oct 18, 2013 6:06 pm

Use ABS plumbers pipe glue the black stuff.. add a nut to bottom of the boss to give you more surface to glue, then you can reenforce it with epoxy or JB built up aroudn the base.
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Re: Side panel "Bosses" (studs)

Postby wingpilot08 » Sun Oct 20, 2013 6:00 pm

Better yet, if you have some extra ABS, make some shavings and mix with the ABS glue and make a slurry. Apply the slurry to the boss/stud, whatever you want to call it, and the the panel. It will make a much stronger connection than using epoxy or JB Weld!
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Re: Side panel "Bosses" (studs)

Postby Maddogg » Mon Oct 21, 2013 7:54 am

Here is what I did. I used 5/16 stud balls i purchased and put a nut at the end for a better base. I used JB Weld for plastic.
stud ball
stud ball

I then put a nut on it for a better base.
nut attached
nut attached

JB Weld
JB Weld
I used JB Weld for plastic.
Let set for approx. 30 minutes. Hard as a rock. Been holding for a week. Looks good. I hope this comes out alright. I have never tried to put multiple pics in before.

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Re: Side panel "Bosses" (studs)

Postby Maddogg » Mon Oct 21, 2013 8:01 am

Forgot a pic. Here is the JB Weld. Bought it at Oriely's for $6.99.

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Re: Side panel "Bosses" (studs)

Postby Ol' Man » Mon Oct 21, 2013 10:45 am

Thanks for the responses. Sounds like a good indoor project this winter.
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Re: Side panel "Bosses" (studs)

Postby Wingsconsin » Tue Oct 22, 2013 9:22 am

I have a few extra stud balls that I can send out...
I bought a package of 20 .... :roll:
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Re: Side panel "Bosses" (studs)

Postby Maddogg » Tue Oct 22, 2013 1:46 pm

Same here. I thought I was buying 10, but it was a package of 2 and now I have 20. Well, 19. I just used one. PM me if you need any.

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Re: Side panel "Bosses" (studs)

Postby REH1966 » Wed Oct 23, 2013 2:16 pm

This will most likely come across as a stupid question but here goes anyway. How do you determine the exact location to place the boss? I would think it would have to be pretty precise and when you put the panel on it would be hard to tell. Thanks.

Rex

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Re: Side panel "Bosses" (studs)

Postby WingAdmin » Wed Oct 23, 2013 3:18 pm

REH1966 wrote:This will most likely come across as a stupid question but here goes anyway. How do you determine the exact location to place the boss? I would think it would have to be pretty precise and when you put the panel on it would be hard to tell. Thanks.

Rex


Put the stud into the grommet. Put some chalk on the end of the stud. Put the cover in place. Look to see where the chalk mark shows on the cover.

That said, you should have a general idea where it should go on the cover by seeing where the old one used to be.

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Re: Side panel "Bosses" (studs)

Postby Maddogg » Wed Oct 23, 2013 3:27 pm

Not to mention the base of the broken stud will still be on the panel.

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Re: Side panel "Bosses" (studs)

Postby Wingsconsin » Wed Oct 23, 2013 3:33 pm

Maddogg wrote:Not to mention the base of the broken stud will still be on the panel.


My broken stud is clean off and level...I have not yeet tried to repair my side cover as the weather is too cold around here...

But I have the stud balls.... (lots of balls) ... :roll:
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Re: Side panel "Bosses" (studs)

Postby REH1966 » Thu Oct 24, 2013 7:16 am

WingAdmin wrote:
REH1966 wrote:This will most likely come across as a stupid question but here goes anyway. How do you determine the exact location to place the boss? I would think it would have to be pretty precise and when you put the panel on it would be hard to tell. Thanks.

Rex


Put the stud into the grommet. Put some chalk on the end of the stud. Put the cover in place. Look to see where the chalk mark shows on the cover.

That said, you should have a general idea where it should go on the cover by seeing where the old one used to be.


That makes sense, never thought about that.

Maddogg wrote:Not to mention the base of the broken stud will still be on the panel.


I will have to check but I think mine is broken down past the stud and into the plastic "riser" it was attached to.

Thanks.

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Re: Side panel "Bosses" (studs)

Postby W3JNP » Fri Oct 25, 2013 9:41 am

The stud balls hold much tighter than the original. I marked placement by first prepping the side cover and then putting the stud in the grommet. I checked for proper length and then used a dab of nail polish on the end to mark where on the side panel the nut should go. I tacked the nut in place first and once I was satisfied everything was lined up I used red lock tight on the stud and permanently glued it in place on the nut. After that I glued everything down solid. I've done one with black ABS cement and another with JB Weld. Both have held up for several months and about 4,000 miles with no sign of coming loose.
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Re: Side panel "Bosses" (studs)

Postby Ol' Man » Tue Nov 05, 2013 10:12 am

Maddogg wrote:Same here. I thought I was buying 10, but it was a package of 2 and now I have 20. Well, 19. I just used one. PM me if you need any.

I tried the PM thingy and obviously I don't know what I'm doing as the message just stays in my outbox. :cry:
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Re: Side panel "Bosses" (studs)

Postby redial » Tue Nov 05, 2013 6:32 pm

A PM stays in your box until it is read. Dont be sad, just give it time to arrive. The receiver was probably shovelling snow, :roll: or if they are in the south, out riding for a while :lol:
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Re: Side panel "Bosses" (studs)

Postby RBGERSON » Wed Nov 20, 2013 6:26 pm

Just an update. I just got a package from Wingsonsin..my bosses!! He sent a bunch and they came priority mail..top draw all the way,

Kudos to Wingsonsin and Thanks..
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Re: Side panel "Bosses" (studs)

Postby Maddogg » Thu Nov 28, 2013 3:43 pm

Update. The JB weld for plastic failed. Had it on for over a month so it had time to cure. The second time I pulled my panel it came loose. The third time it came off. The PO used some kind of epoxy that almost looked like liquid when used but set up solid. The reason I say liquid is because you can see how it leveled itself after application. Anyone seen this kind of stuff before? Any other ideas are appreciated. Thanks.
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Boss with epoxy
Boss with epoxy

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Re: Side panel "Bosses" (studs)

Postby W3JNP » Thu Nov 28, 2013 3:58 pm

I've repaired two studs with this method. I used regular JB-Weld on one and black ABS cement on the other. Both have held up for several months and several thousand miles in both very hot and very cold days. The black ABS cement seems to be the stronger of the two but both are holding up well and I have taken the side panel off an on several times. The studs I am using are the metal ones.
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Re: Side panel "Bosses" (studs)

Postby HALBUDD » Thu Nov 28, 2013 4:06 pm

Maddogg I have had good luck with this, Get the ABS glue not PVC and then get a piece of Abs pipe I just got a coupe of ABS couplings. Take a rasp file or one used for auto body work,get a small cup (not one of your wifes good ones). Use the rasp file and make a half cup of ABS shavings from the ABS coupling.Make sure the area you are going to put the stud on is clean ruff it up with some sand paper. Mix the ABS glue in to the cup of shavings and make a thick paste out of it use this to glue down your stud and around it like the pic you showed. Let it set up for 24 hrs this paste will melt its self and bond in to the side cover making it a part of the cover instead of just glued to it. I have used this to fix cracks in my ABS saddle bags, Good luck-------------------Hal
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Maddogg
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Re: Side panel "Bosses" (studs)

Postby Maddogg » Thu Nov 28, 2013 6:57 pm

I don't have the abs bosses anymore. I replaced them with the metal stud balls. Will the abs glue to the metal stud ball? Never tried that.

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Re: Side panel "Bosses" (studs)

Postby W3JNP » Thu Nov 28, 2013 7:20 pm

Yes. I attached a nut at the base of the stud ball to provide a larger surface for the ABS cement to adhere to. I also cleaned the surface of the side panel so it was down to the bare plastic. I used red locktite on the nut and stud ball once I knew I had the length correct. This photo was when I used the JB Weld.
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Re: Side panel "Bosses" (studs)

Postby HALBUDD » Fri Nov 29, 2013 12:27 am

Yes the ABS paste that you will be making will melt in to the side panel,just apply it just like the one that has jb wield. The jb wield relies on it gluing to the side panel only,the ABS glue and paste will become part of the side panel as if it were made that way. Just make sure you cover the bottom bolt good so it cant pull out.--------------------------Hal


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