TRUNK CORNER CRACKED !

[Bulldogx11]

When I got my 94 voyager it had a crack on the right corner of the top trunk lid. I noticed it got alittle bigger ,but when I went to Americade prolonged high way speeds and bad roads i looked at my bike and the corner of my trunk lid was just barely hanging on (about inch by inch triangle) .luckily i got the piece off before it fell off. The piece fits back in nice but the inside of the trunk is the has the weather seal in the way of where i would do repair. anybody had this or similar problems with the body parts? If you have what is the easiest to use for repair from the back (inside) ive heard fiberglass ,j-b weld.,epoxy maybe ( clearance is a issue). I noticed that the lid was rubbing on the bottom lip where it cracked on the corner is there an adjustment to keep it from doing that? If i did want to glue the piece in place first then do repair in the inside what kind of glue would work on this plastic? Thanks for your help

[chevyman1]

I found that ABS pipe cement works vary well make sure its ABS only cement the malty (ABS/PVC) cements do not seem to work as well.
You should be able to pull the rubber seal off to fix it

[cushman eagle]

I very recently repaired a plastic farm tractor timing cover with JB weld,and it seems like it will do the job.I have no way to know how it will hold up.The alternative ,which I told the customer, was $500 plus for parts and labor to replace it.I will probably find out sometime the life span of the repair.

[SgtSlag]

Mine developed a crack in the corner, as well. I had used ABS Pipe Cement (local hardware store) before, so I, too, used it on mine. The ABS Cement is ABS plastic suspended in a solvent: when the solvent evaporates, the ABS plastic is left behind. It has held up now for 3 years. I would, however, recommend checking/re-applying every year, to prevent a small crack from growing, over time and miles.

To effect repairs, I put masking tape (any tape will suffice, but a smoother finish can be had using packing tape...) over the outside of the crack. Then I used the in-the-can brush to apply the thick, viscous glue to the cracked area. I recommend several thin coats -- don't try to do it in one, heavy go. It cures within 30 minutes, if thin coats are used. After it is built up enough, you can sand the end result, if necessary (usually not needed, but if you want it just so...). After it has fully cured, you simply peel off the tape. Polishing/painting can be done, if desired. Cheers!

[Bulldogx11]

Thanks guys ,so the best stuff to use is ABS only cement i'll give it a try. What about the clearance issue is there any way to adjust or shim the hinge to get alittle more clearance ,I was thinking maybe a thin rubber washer on hinge? and my piece is totally broken out so if the cement sqeezes out crack on to paint will it come off paint? Thanks again for your help

[chevyman1]

I would put the cement on the edge of both peaces secure it somehow then wipe the cement off the paint before it dries.
I would also use pipe cement primer, it softens the plastic that makes the cement get a better hold on the plastic making the joint stronger.
You don't need a lot of cement a light coating should do it.
It sets up fairly quick but I would give it overnight before you do anything with it.

[SgtSlag]

Be warned, if you try to wipe it, it will smear a bit, and dry in the process... The solvent is highly evaporative. I've smeared it, trying to wipe it off, and it left a thin, matte coating of plastic behind. Again, use tape to mask it, applying it to the outside, and apply the Cement on the inside only, where you won't care how it looks. If necessary, you can always buff it, paint it, whatever. Cheers!

[lockwoodjohn]

Hi Everyone,
Just fixed mine today! Wife noticed it last night. Was just holding
On by a hair, Removed it so I would not loose the part. I used Devcon
5 minute epoxie . I held it in place with a little Kant twist clamp until
The epoxie was dry, About a hour in the sun. Wiped out side of area with a paper towel / acatone. Went for a ride corner piece still tight
looks good, Hopefully it will stay that way.
lockwoodjohn

[SgtSlag]

lockwoodjohn, the only real advantage to using ABS plastic glue, is that it seems to be what the trunk is made of. If done carefully, it can also give a seamless repair (big "if", for me...). Epoxies will work. Glad to hear you were able to make your repairs. Happy riding! Cheers!

[lockwoodjohn]

Thanks Sarge,
Went for a cruse today, Repaired corner still there. Is it possible
That the reason the corner broke was I had the tour back adj. All the way back to give passenger more room between us. I also left it loose on the slides. After repairing it I tightened the bottom bolts in the tourpack, I figured I will not be moving it forward anytime soon!
Take Care,
lockwoodjohn

[SgtSlag]

The trunk is large, and being plastic, it can crack from both age, and stress over the years. I guess I would suggest keeping things snug (not necessarily 'tight'), just to keep things from falling apart...

A friend had an '81 Gold Wing. Went for a ride one day (around three years ago, now), and the front fender lost a bolt, and it fell forward, onto his front wheel, locking it. He went down, suffered some broken ribs and a punctured lung, a concussion, and various bumps, bruises, and scrapes! Make sure to go over the bike, at least once per year, and tighten everything to proper torque. Make sure to use an inexpensive clicker-torque wrench (around $20, at Harbor Freight) to ensure all is properly tightened, especially the oil plugs, to avoid stripping them out. The proper torque values are listed within the FSM. Cheers!

[Mr Jensee]

lockwoodjohn, the only real advantage to using ABS plastic glue, is that it seems to be what the trunk is made of. If done carefully, it can also give a seamless repair (big "if", for me...). Epoxies will work. Glad to hear you were able to make your repairs. Happy riding! Cheers!

The plastic body of this bike is (black) ABS. If it weren't the glue would never work. I repaired a split in my saddle bag lid several years ago with ABS glue and it is like it never happened.

[Bulldogx11]

Hi ,I fixed my trunk piece with the ABS cement u guys recommended ,so far so good I put on maybe 400 mi so far and its holding up. When I was workin on it I noticed that the corner were it broke was rubbin so I took a piece of black plastic maybe a 1/16 thick and shimmed out the hinge on that side,and it stopped it from rubbing where the repair is. I would look for wear /rubbing marks where the trunk and trunk lid meet and adjust to prevent any future problems. Thanks again for all your help.

[Mr Jensee]

Thats what we are all here for!