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Rear tailight cowl

  • Thread starter Thread starter drhach
  • Start date Start date
D

drhach

Guest
Hi Everyone, during the disassembly process, all three of the bolts that held my cowl, sheared off. They were all really rusty and looked like they had seen better days. Needless to say, I want to reattach the cowl, but I can't seem to get the sheared bolts out of the cowl. Has anyone ever removed these before? The back two look the were possibly inserted from the top. The front one looks like it was molded in to the piece. I wanted to ask if maybe I was missing something obvious before I attempt surgery. Thanks.
 
1978 Gs1000

1978 Gs1000

chiphead said:
I suggest you post the year make and model.
Click to expand...

That's a great suggestion. I make that same mistake often on another forum for a different bike. I assumed this was the 1978 GS1000 forum.
 
We don't have a specific forum for years and models.

Sorry I can't help you.
 
Billyboy said:
We don't have a specific forum for years and models.

Sorry I can't help you.
Click to expand...

Ok, thanks anyways. I'll unsubscribe from this forum and go home to wait until somebody starts one for my bike.
 
drhach said:
Ok, thanks anyways. I'll unsubscribe from this forum and go home to wait until somebody starts one for my bike.
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Is that a joke?
This forum covers all GS's from 76 to 85. All models. Just not specificly.
 
Billyboy said:
Is that a joke?
This forum covers all GS's from 76 to 85. All models. Just not specificly.
Click to expand...

Yes, it is a joke, in response to what I also thought was a joke on your part. I know there are no specific forums for years and types. I've been reading this forum for a few years now. Even though I don't have a lot of posts, I'm pretty familiar with "the deal" and most of what goes on here. I forgot to include that info in my initial question. When I commented about bike specific forums, I was merely referring to the fact that the bike that I own is all that I think about, and that I forget sometimes that there are other types of GS's out there besides 1978 GS1000's. As such, I usually forget to mention what type of bike I have, because for me, it is a given that it is a 1978 GS1000. I tend to forget that there are all shapes, sizes and flavors of GS out there. Please don't take offense. Sometimes my sense of humor is way too subtle for my writing abilities. This is especially true for people who don't know me.

By the way, any suggestions as to how I might get the sheared mounting bolts out the rear cowl of a 1978 Suzuki GS1000? They are still in there.
 
Could you post pics? I really have no clue in any way whatsoever as to what bolts you are refering to. But i have a 550L, so no fairing. But one thing i have learned, where there's a will, there's a way.

Post a pic, and i might be able to help you figure something out.
 
Might be easier to replace the tail piece. I see 'em pop up on ebay all the time. Otherwise, you probably need to drill them out & run a bolt from the top.
 
Tom MLC said:
Might be easier to replace the tail piece. I see 'em pop up on ebay all the time. Otherwise, you probably need to drill them out & run a bolt from the top.
Click to expand...

That's what I was thinking.

BTW: I know what you mean. I feel the same about my 78 GS1000.
 
Don't you love how the lack of vocal inflection and body language complicate the written word? ;-)
 
t3rmin said:
Don't you love how the lack of vocal inflection and body language complicate the written word? ;-)
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Very much so. That's why people don't line up to but my books. They wouldn't understand what I was talking about. Also, they don't line up to my books because I haven't written any. But that's not the point here. As far as the cowl goes. I am way too cheap to just go out and buy another one. My wife will vouch for my cheapness. So, unless I destroy it while trying to fix it (which is likely). I have to try to get those bolts out. Plus, I don't like thinking that the bolts may be smarter than me. I have included a picture for those of you who don't know what I am referring to. I think in the end, I'll try to drill them out and put new ones in. I think the bolts are molded in to the assembly.


IMG_3420_1.jpg
 
I'm pretty happy with how it came out. I heard green paint makes your bike go faster. I think those caddy taillights should look good too. They fit in the housing almost like they were meant to be there. Someday the damned thing may even run.
 
Here's a thought. First, remove what's left of the studs that are pressed into the plastic. I think a little heat might help this process. Obviously you don't want to melt the plastic but sort of "relax" it. You might even be able to cut a slot or two into the plastic to facilitate removal because it will be fixed in the next step anyway. Then get some appropriate sized bolts, place the heads in the now vacated holes in the cowl and apply a generous filling of JB Weld. This should stick the bolts in there just fine. I had originally thought drilling out the old studs and then tapping would work but this method might be easier and just as effective. Don't overtighten and use stainless steel bolts and nuts and you'll never have to worry about them rusting again.
 
I am considering using a heat gun too. My concern about drilling is that I won't get the drill bit centered and everything will go haywire. The only issue that I see with the heat gun is the one of the bolts doesn't have a hole that I can push it through after I heat it. Well see. I'm pretty good at breaking things. My motto is "If I can't fix it, I'll fix it so no one can". I'll mess with it this weekend. This may be my excuse to make a new cowl out of fiberglass. "Sorry honey, I had to. The old one was ruined."
 
Well, if you end up having to make a new cowl, why not follow the theme
you have already started and make it a '59 Caddy FIN? :shock: \\:D/


.
 
Steve said:
Well, if you end up having to make a new cowl, why not follow the theme
you have already started and make it a '59 Caddy FIN? :shock: \\:D/


.
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I was thinking the same thing. Although maybe not so big. I got the studs out. They have thes giant knurled heads on them. I'll post pics if I can ever find my camera. They are very overbuilt. I ended up separating the two halves (they are riveted together). After that, I started drilling from the top. I expected to se see a bolt head or something. The drill just kept going though. Eventually, the plastic got warm enought that it was very pliable, so I pulled one of the hot bolts out. I'll have to use some long bolts and a big washer but it'll work. I've been aching for an excuse to some fiberglass work, after all of this, I may do that anyway.
 
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