Broken Top Case Hinge - BMW Luxury Touring Community
 
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post #1 of 11 Old Feb 25th, 2012, 5:08 pm Thread Starter
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Broken Top Case Hinge

At some point in time last summer the left top case hinge on my 2003 LT broke and I have been trying to fix it ever since. I have concluded that there is no commonly available adhesive while will stick to the plastic used in this are and so now I turn to some sort of mechanical solution. I am not in a position financially to replace the case and I know that I am hampered by my lack of mechanical aptitude.

I cannot put new screws in as there is nothing on the outside edge to screw them in to, likewise replacing the rivets (they are still firmly attached).

I apologize for the shallow depth of field and lack of good focus in these images. I was holding the camera in one hand and the light in the other. If anyone has any further advice for me I will be most grateful for any and all help.

Here's what it looks like when the hinge is seated. This will only last a few minutes, roads here are quite rough.


This is what it looks like after a pothole jars it loose.


This is the underside of the hinge.


This is what's underneath the hinge


And this is the edge.
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post #2 of 11 Old Feb 25th, 2012, 7:30 pm
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Re: Broken Top Case Hinge

Mark,

Late in the fall there were a couple other folks that had the same problem. They posted couple ways to deal with this, I am sure if you do a search you would find their fixes, photos were included.

John Baker

2005 BMW K1200LT
1979 Suzuki GS1000E
1978 Honda CB350
1975 Suzuki GT380
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post #3 of 11 Old Feb 26th, 2012, 7:16 am
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Re: Broken Top Case Hinge

Mark:
Isn't this the same post you did back in September? My solution really isn't hard and has worked really well. you should give it a try.

Ray
http://www.bmwlt.com/forums/showthread.php?t=63805

Ray Rau
Brewster, NY
'99 LT - Champagne
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post #4 of 11 Old Feb 26th, 2012, 9:21 am
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Re: Broken Top Case Hinge

ray just checked out your repair looks like a pretty good solution
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post #5 of 11 Old Feb 26th, 2012, 10:06 am
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Re: Broken Top Case Hinge

Quote:
Originally Posted by RiderRay
Mark:
Isn't this the same post you did back in September? My solution really isn't hard and has worked really well. you should give it a try.

Ray
http://www.bmwlt.com/forums/showthread.php?t=63805
Mark, this is the repair I was thinking about, nice fix Ray. Mark if you are reluctant to try this repair you could always look on Ebay. There is a blue trunk listed there for a $50 dollar bid right now. The top is broken but the bottom looks ok, ask the seller for additional photos to be sure.

John Baker

2005 BMW K1200LT
1979 Suzuki GS1000E
1978 Honda CB350
1975 Suzuki GT380
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post #6 of 11 Old Feb 27th, 2012, 8:08 am Thread Starter
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Re: Broken Top Case Hinge

Clearly I did not go back and look at what I said when this originally happened and so I apologize for going over this well-trodden ground once before. The duplication of the photos was particularly embarrassing.

I am looking at the suggestions that were made to see what I might be able to do given my abilities and the tools I have. I will certainly try some other things before resorting to more drastic solutions. Thanks to everyone for their input.
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post #7 of 11 Old Feb 27th, 2012, 9:18 am
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Re: Broken Top Case Hinge

Quote:
Originally Posted by markc
Clearly I did not go back and look at what I said when this originally happened and so I apologize for going over this well-trodden ground once before. The duplication of the photos was particularly embarrassing.

I am looking at the suggestions that were made to see what I might be able to do given my abilities and the tools I have. I will certainly try some other things before resorting to more drastic solutions. Thanks to everyone for their input.
Sorry I didn't intend to point out you asked before, just remembered someone had that problem and there were a couple solutions.

Here is the link to the Ebay trunk, looks like a cheap fit to me, just ask the guy for more photos to see if the bottom is good. http://www.ebay.com/itm/BMW-Top-Tunk...item2a1a4d66d0

John Baker

2005 BMW K1200LT
1979 Suzuki GS1000E
1978 Honda CB350
1975 Suzuki GT380
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post #8 of 11 Old Mar 7th, 2012, 7:47 pm Thread Starter
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Re: Broken Top Case Hinge (Fixed!)

I decided to check into the idea of a body shop plastic welding the hinge back together. Mike's Motorcycles in Boulder directed me to A.C. Collision Repair, also in Boulder. Mike Williams, the owner, did what I think is a marvelous job for a fair price ($150) so I think this particular saga is at an end. Thanks to everyone for their suggestions.

Here is what is looks like now. You can refer to my multitude of other photos to see what it looked like in its broken state.

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post #9 of 11 Old Mar 23rd, 2012, 3:25 pm
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Question Re: Broken Top Case Hinge

Same problem. I drilled out the pop rivets and used JB weld to epoxy the plastic in place.
#8-32 screws to replace the rivets. Hope it works!
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post #10 of 11 Old Mar 30th, 2012, 11:35 pm
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Angry Re: Broken Top Case Hinge

Quote:
Originally Posted by Spenceer
Same problem. I drilled out the pop rivets and used JB weld to epoxy the plastic in place.
#8-32 screws to replace the rivets. Hope it works!
JB weld did not work.
A piece of aluminum angle works well along with a long hose clamp until I can get a
new(er) lower trunk. Looks awful..
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post #11 of 11 Old Apr 1st, 2012, 12:02 am Thread Starter
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Re: Broken Top Case Hinge

I really recommend going to a body shop and looking into getting the plastic welded back together. At least find out if it will work in your situation. I have been very happy with how the repair turned out for me.
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