Making tabs for side covers, 1983 GS1100E

[oregonjake]

What would be the best method to make new tabs for side covers? I have bondo but am not sure as to what material to use and how to fashion them the right size. Ideas please.

[loud et]

I don't think automotive bondo is a very good choice if that's what you have.
2 better products would be pc7 or Quicksteel. Two part putty that you knead together. Strong and hard.
If you have a little bit of the original tab left and can form the putty around it , it will hold well.
As far as the shape of the tab, we'll copy the others I guess if you can.

[loud et]

You really have to get creative when it comes to rebuilding sidecover tabs/ clips.
Its trial and error sometimes.

[isleoman]

Search is your friend. Many post with good results.

[oregonjake]

Thanks for all the advice. I checked the threads and have decided on trying rare earth magnets and 1/2 inch dowels. I figure since the frame is steel and rare earth magnets are quite strong, it eliminates the need for rubber grommets and the chance that they may break again (no offense to those who have had their work last for years). If magnets do not work, I can try other methods, or just pay for good used side covers when they show up on ebay. Thanks again for all the great advice.

[Deuce]

I don't think automotive bondo is a very good choice if that's what you have.
2 better products would be pc7 or Quicksteel. Two part putty that you knead together. Strong and hard.
If you have a little bit of the original tab left and can form the putty around it , it will hold well.
As far as the shape of the tab, we'll copy the others I guess if you can.

I used bondo to hold a tab I made to my side cover. Haven't had any issues yet. JB weld didn't work.

[sedelen]

I used a piece of copper from a 1/2" piece of tubing. Used the old tab as a template. Cut a groove to have a protruding piece of sidecover plastic fit into tight. Glued and that was it. Wasn't pretty, but functional. Could be made to look good with a little bondo and paint I suppose.
Problems with these tabs are old plastic, old age makes the brittle I think. The replacements for your rubber grommets these fit into have a new part number, but the grommet holes are smaller and the tabs don't fit into them, I broke a tab trying.


I also made a new post for one that had broken. Used a screw, made the same size and shape of the old post, and screwed it into two flat washers for a tight fit. Roughed up all the metal and plastic before I applied super glue. Worked.

[Arronduke]

http://www.thegsresources.com/_forum/showthread.php?224500-GS1100EZ-side-cover-tabs-replacemnt-easy-and-works-a-treat&highlight=plastifix

This is how I did it.
Amazing stuff and working great.
Easiest method also