Happy Trails aluminum pannier repair - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 6 Old 05-03-2018, 05:55 PM Thread Starter
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Happy Trails aluminum pannier repair

I am a klutz. This is where I park at work. This morning, riding up to where I'd back up to that spot, I got too close to the fence and my right-side Happy Trail aluminum pannier hit the edge of that fence. Derp.

The damage was that the nut on one bolt was "ripped through" the aluminum, and the nut on the other bolt was "partly ripped through". (Picture) I've got a plan for repairing it myself, but I have a question on one step of the plan:

  1. Using a couple of wood blocks and a hammer, hammer things flat where those holes are.
  2. Get a sheet of aluminum big enough to cover both holes with a lot of margin. (The holes are about 4" apart, so I'm thinking have a 2" margin all around by getting a sheet that's about 4" x 8".)
  3. Attach the sheet to the inside of the pannier. This is where I have a question: How?
  4. Drill new holes through the sheet where the old holes are.

So what would be the best way to attach that new aluminum sheet? I'm thinking maybe pop rivets, one on each corner and one in the middle of each long side. But I Know Nothing in this area, so I welcome any better suggestions. Thank you all for being here!

2011 V-Strom DL650 - Canadian in Tarzana CA
Previous: 1994 Yamaha Virago XV535

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post #2 of 6 Old 05-03-2018, 06:41 PM
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Epoxy with good surface prep.
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post #3 of 6 Old 05-03-2018, 08:17 PM
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JB Weld. I'd skip the metal plate and fill the hole with JB Weld and then spread it out in a thin layer on the inside.
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post #4 of 6 Old 05-03-2018, 09:39 PM
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what Stalky said. just b sure to prep the area
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post #5 of 6 Old 05-04-2018, 04:02 PM Thread Starter
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I confess, I've never used JB Weld for anything. I'd be a bit nervous to use it alone. Luckily, I found a place here in the L.A. area who'll cut me (or anyone) a sheet of 0.050" aluminum to my specs for $5-6. So I'll do that with the JB Weld. For prep, I saw that sanding and acetone are recommended for Al.

Question: "Regular" JB Weld? There are a few different varieties out there; so regular's OK on Al, or should I get a different flavour?

2011 V-Strom DL650 - Canadian in Tarzana CA
Previous: 1994 Yamaha Virago XV535

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post #6 of 6 Old 05-04-2018, 11:16 PM
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I use it quite a bit. I have 30+ year old wheel barrow with a plasitc bucket that is probably 80% JB Weld now.

I'd use regular. It has a longer setup time (more time to work with it) and a longer cure time (gotta wait). In your application I don't think it would matter, the adhesion for both is the same.

2020 Eastern V-Strom Rally (website) - May 14 - 17, 2020
__________________________________
2006 Suzuki V-Strom DL650K
1986 Honda Shadow VT700C
1974 Suzuki TM-250
1966 Triumph Bonneville T-120R
1965 Suzuki 80
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