Repair/Strengthener Hinge Kit

[Bob Denman]

Congratulations to Bob Denman (2014 RTS) and Pontow (2015 RTS) as the two product testers for the hinge project. Many thanks to all of you that ask to help. WE will start with these two and see if we need to expand it from there!
I have ran into a snag (doesn't that always happen) with the outer bracket. Getting the secondary cut has to be done just right. Then the part can be bent and drilled and then powder coated. It looks like I may have to purchase a $400 shear to make these precision cuts. We'll see how it goes. Everything else is ready to ship. This part is critical as it will strengthen the lid side from breaking back from too much pressure. The back bracket will strengthen the hinge area from breaking out in the case of overfilling or something in the way of shutting.

 

[Roadster Renovations]

ray: What have I done??!!?!?:yikes:

 

[Roadster Renovations]

Creating outer jigs

A member was talking about all the irregular surfaces on the bracket area and in order for the outer brackets to fit correctly, i have had to make a form or jig. That is what we are doing today. Ready to braze the first one of three.

 

[Bob Denman]

ray: What have I done??!!?!?:yikes:

 

[Roadster Renovations]

Finally - Test Kits Done!

Will ship on 7/12/15!

 

[Bob Denman]

:clap:
Doc,
These things ARE gonna come with a batch of instructions; right? :shocked:
I'll be sure to fire up the camera, and get some photographic of the entire episode! :thumbup:

 

[Roadster Renovations]

Bob, they are so simple........uhhh, yeah 3 pages! :roflblack::roflblack::roflblack:

Actually, they are very simple to install. The main key is lay your parts out correct side up and correct position first. The rest is very easy. You actually don't have to completely remove the hinge to install this! But, yeah, there are 3 pages and a couple of diagrams. The parts that are position critical are marked on the back.

 

[Bob Denman]

This is why I volunteered: if I can manage to perform the installation; ANYONE can! :thumbup: nojoke

 

[Bob Denman]

Besides: How tough can it really be? :shocked:

 

[pontow]

Bob, they are so simple........uhhh, yeah 3 pages! :roflblack::roflblack::roflblack:

Actually, they are very simple to install. The main key is lay your parts out correct side up and correct position first. The rest is very easy. You actually don't have to completely remove the hinge to install this! But, yeah, there are 3 pages and a couple of diagrams. The parts that are position critical are marked on the back.

Hey Doc, saw my name as a tester and got pretty excited! Then I remembered that I actually have to figure this thing out. Doh! Looking forward to 3 pages of light reading and I'll do my best to get some good pics along the road to installation.

Let me know the shipping method and any tracking #'s and I'll watch for the kit to arrive.

 

[Roadster Renovations]

Hey Doc, saw my name as a tester and got pretty excited! Then I remembered that I actually have to figure this thing out. Doh! Looking forward to 3 pages of light reading and I'll do my best to get some good pics along the road to installation.

Let me know the shipping method and any tracking #'s and I'll watch for the kit to arrive.

Going out today by USPS. Same for Bob!

 

[Bob Denman]

 

[garb55]

Doc I have not had a problem with my hinges so till I looked at this thread I never paid any attention to them
After looking at them I think that the inside peace could be made to go all the way across so that both front and back hinges are connected with metal
Just did not know if you thought of this
Should not cost much more and should make the indestructible

 

[Roadster Renovations]

Doc I have not had a problem with my hinges so till I looked at this thread I never paid any attention to them
After looking at them I think that the inside peace could be made to go all the way across so that both front and back hinges are connected with metal
Just did not know if you thought of this
Should not cost much more and should make the indestructible

Thanks for that. The outer brackets are designed to have some "spring" action to integrate with the slight movement of the plastic. The way it is designed the more the plastic flexes towards the center of the bike the more load the outer brackets take up. My front hinge was so broke it had 1/4" of play back and forth and was barely held at the top. When I installed the outer bracket and tightened it up it immediately stopped wiggling and was like it had allways been. The outer bracket makes 1/2" of contact on both front and back in a solid area of the case plastic. Longer bolts with shorter heads compensate for the thickness of the outer bracket to make sure both bolt heads do not press against each other with the lid closed. The longer bolt sticks out far enough through the metal bracket so that the inner bracket can be nutted on. The inner bracket makes contact with both the metal plate and the raised and reinforced area beside where the factory metal plate fits. This covers the hinge from outer and inner pressure, making it much stronger than before. The matte black powder coat will not only look natural in place, but the rough friction surface will help to keep it in place. Should never have an issue. I wouldn't throw a bowling ball on the lid to test it, but for normal usage it will help to disperse and distribute the forces that have caused it to break in the past.

For those of you 2014 RT owners that are wanting to get these on, I will have 4 sets ready for sale by the weekend. Send me a PM and I will invoice you. They are going to run about $65, which includes shipping. They will come with a lifetime warranty against their breakage. There is nothing that can break on them. Title your PM with Side Case Upgrade/Repair Kit.
Obviously, you can wait on Bob's report, but for the 14' RT's I know the kit will fit.

 

[trikermutha]

Are the trunk hinges that cheap and break the way you are describing?

 

[Roadster Renovations]

Are the trunk hinges that cheap and break the way you are describing?

Well, the area the hinge fits is partially hollow so that the bottom has just a small plastic area. They have placed guides that go back beside the void area that correctly position the steel plate the bolts thread into. Why that could not have been made solid I don't know.
Prior to this kit the only fix was to replace the complete inner case. Take a look at yours and you will see what I am saying.

 

[Roadster Renovations]

DIY instructions

I posted the instructions in the DIY area for the upgrade/repair kit so everyone can see how easy it is to install.

 

[Bob Denman]

Doc,
Are you set up to accept PayPal as payment for them?
If so; please PM me your account info, so that I can pay for mine! :thumbup:

 

[Roadster Renovations]

Doc,
Are you set up to accept PayPal as payment for them?
If so; please PM me your account info, so that I can pay for mine! :thumbup:

That's Ok, Bob! We got you covered! Don't want to upset the misses!! :thumbup:

 

[garb55]

Thanks for that. The outer brackets are designed to have some "spring" action to integrate with the slight movement of the plastic. The way it is designed the more the plastic flexes towards the center of the bike the more load the outer brackets take up. My front hinge was so broke it had 1/4" of play back and forth and was barely held at the top. When I installed the outer bracket and tightened it up it immediately stopped wiggling and was like it had allways been. The outer bracket makes 1/2" of contact on both front and back in a solid area of the case plastic. Longer bolts with shorter heads compensate for the thickness of the outer bracket to make sure both bolt heads do not press against each other with the lid closed. The longer bolt sticks out far enough through the metal bracket so that the inner bracket can be nutted on. The inner bracket makes contact with both the metal plate and the raised and reinforced area beside where the factory metal plate fits. This covers the hinge from outer and inner pressure, making it much stronger than before. The matte black powder coat will not only look natural in place, but the rough friction surface will help to keep it in place. Should never have an issue. I wouldn't throw a bowling ball on the lid to test it, but for normal usage it will help to disperse and distribute the forces that have caused it to break in the past.

For those of you 2014 RT owners that are wanting to get these on, I will have 4 sets ready for sale by the weekend. Send me a PM and I will invoice you. They are going to run about $65, which includes shipping. They will come with a lifetime warranty against their breakage. There is nothing that can break on them. Title your PM with Side Case Upgrade/Repair Kit.
Obviously, you can wait on Bob's report, but for the 14' RT's I know the kit will fit.

Thanks Doc
I will PM you I want mine stronger before they brake