Rear shock stud end repair

My 650rj has a case of broken shock mount threads. A Previous Owner had snapped off the threaded parts of the upper shock mounts on both sides. His solution to keep the shocks from coming off was to weld them in place. Needless to say, now they couldn't pivot, plus they were actually weaker as the top rings were compromised.

It took some time to figure out the solution. I wanted to stay as original as possible, maintain strength, and use factory equipment. The studs are no longer available, and I was not a out to try extracting ones from another frame, and then have to extract these, and still have to weld ones I to the holes.

So, here's my fix-- for those of you who have similar issues, I can now supply you with these parts!!

I let the pics speak for themselves, other than captions:


---Here we go
Starting time

The problem


Grind threads flush to stud

Center punch

 

Step through drill bit sizes until desired hole is drilled


Tap the hole-- I used a regular tap, then a "bottoming tap" (shown)

The magic part!!

Installed with a couple locked nuts to torque it into place. Use RED locktite

All better

 

Add the washer, standing handle, acorn nut

Look at the clock-- only one hour!!


The only things I used: hearing protection/eye protection, grinder and dremel, center punch, drill and bits, taps, wrenches, and red locktite.

If anyone needs new ends for doing this project, contact me and I can have a set made for you!

Dave Fox

 

Great write up and good work! A++

 

Ok, pictures make this perfectly clear. I get it now, but I still have 2 questions.
1. How did you ensure that the hole you drilled was going in straight on,
2. How many sissy bars do you have hanging on the wall there?
The legend of your parts hoard grows...

 

This is one way.

The V shaped sliding part is a tool to find the center of any round stock. Ther are other types of center-finders, and some are pretty easy to make at home.

 

That is a cool square. A lot of these fabricating tools are very new to me. Finding the center I get, but I still can't visualize what Dave would be doing to ensure that the hole goes in straight. There is not much there to place the square against, and a bunch of obstacles around it too. I don't have any real need for this info, my shock mounts are fine. However, since I am new to this, I want to learn as much as I can from others, so when a problem arises, I'll be ready! Someday, I'll have to learn about the electrical stuff too. I read the posts, but my eyes glaze over and my mind wanders... Thanks to all who have taught me!

 

Well..... I drill slowly and carefully--- I stop and check every several seconds carefully to make sure the drill is staying in a straight line from the side, and I can easily see if it stays in a straight line from the top.

In short, if | and __ are straight, then the + will be straight.

How did I make sure it was centered? I used my ruler and marked halfway, both horizontal center line and vertical center line.

 

Nicely done, Dave. This makes a lot more sense than your other, picture-less post that preceded this one, but what in the holy hell is that thing? (And don't say it's magic!)

 

Actually, looking at it more now: is it just a regular threaded rod that got lathed to a narrower diameter on one end, then tapped/died to the desired thread?
I realize you may have explained that in the other post already, but I'm too forgetful and too lazy to find your post and re-read.

 

Yes, but go to your Local hardware store and ask for a step-stud that is:
M10x1.25px14mm/m8x1.25px8mm and They will have no clue, tell you it's a wrong size, and tell you it's not available, and it's the wrong one, or it'll have to be custom-made, etc...

 

I like that. Clean. Quick (relatively) and non-destructive (i.e. un-doable)

 

Excellent solution - very helpful write up - many thanks

 

Thanks!hopefully it helps someone

 

Great repair Hogfiddles.

 

Very Very Nice Repair.... Great work!!!

Every time I THINK I've seen the stupidest backyard repair, I get to see yet another. The P.O.'s welding that shock is definitely in my top ten of dumb arse repairs I've seen on these old bikes.

 

Thanks!!
Yeah, I wish I had taken a close-up of the shock while it was still welded on the post! I do have a couple pics of it when first got it.... I'll have to see if its visible on those----

 

I await the results...

 

A thing of beauty!