Repair options for case damage?

[Cwoods]

Ok, 1981 1100E and still going over the bike making a list for things to do, buy etc. Took off the side cover to find 2 of the 3 bolt mounts had been over tightened by someone and broke a couple bits off the case side threaded mount points. The bolts were still holding fast with the missing pieces but I want to better this situation as well as do away with the piece on the one mount that is open to the outside.
Any opinions? I have been thinking mabey building these 2 spots back up with some JB weld perhabs?? Open to ideas. Thanks guys.

[Cwoods]

Here's a couple more pics

[Cwoods]

And last....

[Rich82GS750TZ]

Hopefully, the PO didn't do the same to any covers that are suppose to keep oil inside the engine. Whatever you can do to just make sure the cover doesn't fall off, and that nothing flies in there and interferes with your ignition mechanism. It's electronic so shouldn't be as bad as if it was open points.

[Cwoods]

Thanks Rich, had the clutch cover and stator cover off and all is good there....havent adjusted valves yet, lots of silicone where a gasket should be and my only oil leak as well. I think it just needs a good gasket there but we shall see.
Back to the case repair I'm wondering if I had the bolt in the hole and JB welded around it on the broken side if the JB would bond to the bolt after it cured or would I be able to back the bolt out afterwards....

[Steve]

Clean the areas you want to repair immaculately with brake cleaner. Put a light film of Vaseline on the bolts, screw them in so there are a few threads past the last area that is broken. Glob on some JB Weld. Might want to use the "quick" formula, as it sets up a LOT quicker.

And get some proper bolts. Those two with the straight slots belong in the garbage bin.

.

[Cwoods]

Clean the areas you want to repair immaculately with brake cleaner. Put a light film of Vaseline on the bolts, screw them in so there are a few threads past the last area that is broken. Glob on some JB Weld. Might want to use the "quick" formula, as it sets up a LOT quicker.

And get some proper bolts. Those two with the straight slots belong in the garbage bin.

.

Excellent on the Vasaline! I was thinking that may be a possibility and you just confirmed it for me!
As far as the bolts go I am already planning for a new bolt kit for all the side covers for sure.
Thanks for the reassurance

[Grimly]

The JB Weld will probably work, but if it doesn't they could be alloy welded up. Such a pair of trivial repairs are a lunchtime job for a good welder and won't cost more than a crate of beer.

[Cwoods]

Thanks for all the input. As a follow up the JB Weld worked fine, I decided to go with the traditional JB over the Fast set JB as the Fast Set is 3000 psi strength vs 5000 psi on the other.... I'm satisfied with it, on with the rest of the bike!

[Steve]

Thanks for the follow-up.

I was suggesting the quick formula so it would set up a bit quicker and not puddle. I was not aware of the strength difference, but I am aware of a difference in heat rating. I think the quick version is only rated to 450°, the regular formula is good to 550°. Either one would be good on engine cases, so I did not bring that up.

.

[portdave]

I have had good success with Quiksteel also for something like this.

[salty_monk]

I saw this stuff demo'd at Sema - it worked really well, I think it would be a good alternative if the breaks were in a more critical spot (i.e. not in a dry area, I'd be more than happy with JB weld where you've used it.

https://www.alumiweld.com/index.html