Broken fairing mounts! - Harley Davidson Forums: Harley Davidson Motorcycle Forum
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post #1 of 15 (permalink) Old 05-26-2012, 06:13 AM Thread Starter
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Broken fairing mounts!

Batwing fairing mounts break. The metal is thin, and over the years, vibration will eventually cause them to fracture and snap. I was also amazed that the lateral pressure the braces are under.

I found one broken during installing fairing mirrors.

(Right side upper mount tab):



So.....there are kits out there to repair these. However, I needed a fix NOW, since the bike was apart, and I'm a CAPP.

OEM metal is 1.65mm thick, including powder coating. I used 2.25mm thick, mild steel.

Cut and shape metal to desired size. Leave about 2.25" of metal after the 90* bend, to attach to existing brace.



Drill hole for mounting bolt to fairing.



Drill 2 holes for mounting to existing brace.






__________________________________________
When the going gets weird, the weird turn professional.... ~ Hunter S. Thompson~

R.I.P. Rubberdown. 1971-2012

"Your Jedi Mind tricks will not work on me...... ~Misinlink-2016~

2005 E.G. Classic
S&S 510 cams
Baisley Oil pump spring
CYCO tensioners
V&H Fuelpak
SE 3.5" pipes
K&N filter
Fueling lifters
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post #2 of 15 (permalink) Old 05-26-2012, 06:17 AM Thread Starter
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Put a towel under where drilling is gonna happen to catch metal bits. Then, clamp a vicegrip onto the braces to keep them together and steady.



Drill the holes to match your mounting hardware. Polylock nuts or serated nuts are preferred, to prevent coming loose again.



After the holes are drilled, use a small magnet and clean up any metal chips from drilling.



Bolt on your mount. I used serated nuts with red locktite. Bracket was removed and painted before buttoning up the fairing.






__________________________________________
When the going gets weird, the weird turn professional.... ~ Hunter S. Thompson~

R.I.P. Rubberdown. 1971-2012

"Your Jedi Mind tricks will not work on me...... ~Misinlink-2016~

2005 E.G. Classic
S&S 510 cams
Baisley Oil pump spring
CYCO tensioners
V&H Fuelpak
SE 3.5" pipes
K&N filter
Fueling lifters
S&S adj pushrods
Swingarm stabilizer
Dave63 is offline  
post #3 of 15 (permalink) Old 05-26-2012, 06:53 AM
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Nice fix....my 04 broke in the same spot...was getting a lot of extra shaking when sitting still...thats a sign it is broke.... also the little mount that went up to the speaker was broke too...

2012 Ultra Classic White hot Pearl..... 2002 Fatboy Concord Purple,
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post #4 of 15 (permalink) Old 05-26-2012, 07:01 AM Thread Starter
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Quote:
Originally Posted by lakeforktx View Post
Nice fix....my 04 broke in the same spot...was getting a lot of extra shaking when sitting still...thats a sign it is broke.... also the little mount that went up to the speaker was broke too...
This is a common problem with these fairings..... Funny part is, they all break once the bike is out of warranty.



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__________________________________________
When the going gets weird, the weird turn professional.... ~ Hunter S. Thompson~

R.I.P. Rubberdown. 1971-2012

"Your Jedi Mind tricks will not work on me...... ~Misinlink-2016~

2005 E.G. Classic
S&S 510 cams
Baisley Oil pump spring
CYCO tensioners
V&H Fuelpak
SE 3.5" pipes
K&N filter
Fueling lifters
S&S adj pushrods
Swingarm stabilizer
Dave63 is offline  
post #5 of 15 (permalink) Old 05-26-2012, 07:25 AM
bud
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Hi Dave , I for one really appreciate all you do ! Thanks ! Dave , Do you think I should on my 2008 Ultra go ahead an fab new structure or piggy back the still sound factory brackets for longivity as I have 17,000 miles on the clock now . Thank you Dave . Bud
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post #6 of 15 (permalink) Old 05-26-2012, 07:36 AM Thread Starter
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I'm under the impression, Bud, some of these kits that are sold as "repair" can be mounted at any time, to PREVENT the stock brackts from breaking......

I'm eventually going to make another mount and replace it (Piggyback it) regardless. It seems it's not a matter of IF, rather WHEN.

Pre-2009 Bikes are effected. This guy's kits include speaker supports as well.





__________________________________________
When the going gets weird, the weird turn professional.... ~ Hunter S. Thompson~

R.I.P. Rubberdown. 1971-2012

"Your Jedi Mind tricks will not work on me...... ~Misinlink-2016~

2005 E.G. Classic
S&S 510 cams
Baisley Oil pump spring
CYCO tensioners
V&H Fuelpak
SE 3.5" pipes
K&N filter
Fueling lifters
S&S adj pushrods
Swingarm stabilizer
Dave63 is offline  
post #7 of 15 (permalink) Old 05-26-2012, 07:37 AM
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Nice clean , easy , inexpensive fix and it can't be seen when the fairing is back on .

Disclaimer : Don't believe anything I say unless you are absolutely sure that I know what I'm talking about .
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post #8 of 15 (permalink) Old 08-15-2012, 10:08 AM
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Metal fatigue is the problem, even the add on fix will break over time. Weilding a bead in the inside corner of each bend will cure the problem once and for all.
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post #9 of 15 (permalink) Old 08-16-2012, 07:33 AM
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If you go welding on the bike with the electrical system hooked up you're looking for trouble !!! Just saying.

Disclaimer : Don't believe anything I say unless you are absolutely sure that I know what I'm talking about .
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post #10 of 15 (permalink) Old 08-16-2012, 07:34 PM
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webco2, yep thats what i did also. working so far....
and the battery was disconnected...
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