Fixing Cracked System Case

[RTNewbie]

I have a broken (cracked) left side case. Has anyone repaired one? How?

[MCMXCIVRS]

I haven't had to fix a crack, but I did repair the broken monting hook on one of mine. For a crack, you could look into having it plastic welded. If its the lid and cosmetics are a concern, you can buy parts for the cases individually.

[jyambrovich]

I'm told by a good friend and multi-bike owner that a product called Plasti-fix is THE THING for fixing cases, side covers, fairings etc. I've looked it up on the WWW and it runs about $36.

Cheaper than buying replacement pieces (for sure!). I hope that helps. If you give it a go, post your experience with it here and INCLUDE PHOTOS!!

[RTNewbie]

I haven't had to fix a crack, but I did repair the broken monting hook on one of mine. For a crack, you could look into having it plastic welded. If its the lid and cosmetics are a concern, you can buy parts for the cases individually.

That is exactly my problem! How did you repair it?

[BuddingGeezer]

I just recently repaired and painted a 1987 K100Lt. The fairing and left mirror had numerous cracks (some completly through). I took a rotary grinding tool with the little barrel sanding thing-a-majig and ground the backside crack. This makes a u-shape furrow and gives the epoxy a greater surface area to bond. After 24 hours grind the outside crack till the epoxy is barely visible and epoxy. This makes a solid epoxy repair. It will be stronger than the original. Epoxy putty is easier to use than liquid epoxy. Then lightly lower the surface and body putty (Bondo). Sand 320 grit, prime, sand 600 grit and paint.

The cases on my LT were textured finished and I wanted a slick finish like the new models. 2 heavy coats of primer, level block sand with 600 grit, color 2 coats, 2 coats of clear. The are beautiful. I believe my bike is #311 on the K bike page.

Use epoxy. polyester is not strong enough. If the cracked area is weak use glass cloth as backing.

[FredRydr]

An alternative to a repair of plastic:

People break R1100/1150 system case lock mechanisms often enough, which are separable from the case proper. Look on the favorite BMW sites and eBay for a used case with a broken lock, and swap your locking mechanism into it. (Make sure you get the correct model case, as I believe there are at least three versions for each side across the entire R1100/1150 and K1200 (old) model lines.)

Fred

[BluegrassPicker]

I have a broken (cracked) left side case. Has anyone repaired one? How?

JB Weld worked well on mine - (the 24 hour kind)

[MCMXCIVRS]

That is exactly my problem! How did you repair it?

I made a new hook from aluminum flat stock to replace it. I used some pop rivets and hot melt glue to attach it to the case. I bent a piece into an L shape, which because of the way the hook hangs on the rail, I slipped through a slot I cut in the case at the underside of the old hook. I also cut away the platic on the protruding portion of the hook base to accomodate the thickness of the aluminum first. I used an angle piece in side to attach to the case, and then fastened the new hook to it with rivets. I countersunk the rivets on the outside of the case so they would not chafe on the rail. The hotmelt glue seals everything up. A bit of matte black paint, and you can hardly tell.

Might have to take some photos to help with that terrible description. :confused:

This was the second time the hook failed on the right case for me. First time BMW warranted it, but the bike is much too old for that now. I figured I had little to lose trying to fix it, it was all ready broken and unusable. Next option was buying a new shell.