Side Panel Repair/Bodgery?

[Suntan Sid]

I need to repair the side panels on my project bike, (Xl125RC), the problem being the plastic lugs, which plug into the frame, holding the panels in place, have snapped off at some point. I am only missing the front lug, the rear is good and the bottom of the panel is bolted to the frame. These are the soft plastic type panels.
The lugs are not available so I can't glue or plastic weld them back on.
I currently have a couple of bodgetastic ideas to save buying more panels.

Idea 1.
Fix a rubber type block to the frame lug and glue velcro to the block and the back of the side panel.
I imagine the drawback with this is that the velcro and the glue will need replacing on a regular basis.

Idea 2.
Drill a hole in the panel and bolt it in place or use Dzuz type fastners.
The draw back with this is, where the bolt/fastner head will be, will no doubt be right where my legs catch the panel.

Idea 3
Ghetto solution, drill a small hole in the top/side of the panel and cable tie it to the frame!

Whaddya think then, anyone been down either of these routes, or do you have better solutions?
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[SQL]

soldering iron and plastic weld it

edit ** I would cast a new lug from plastic using a mold first.

[Val]

Delboy uses cable tie to weld fix the lug:

https://www.youtube.com/watch?v=k7GRNvPSf7k
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[Taught2BCauti...]

Check to see if your local tech college has a 3D Printer, and ask if they will build-up some new lugs as a student project.
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[Matt B]

Can you not attach something like this to the back of the panel so it can still push into the grommet hole thing? Or bend one up to the right size out of a bit of strip metal.

https://i.ebayimg.com/00/s/ODAwWDgwMA==/z/7Z8AAOxy3zNSmdAj/$_57.JPG
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[WD Forte]

3D printing sounds like a plan
There's a Hackspace here in Bristol where a few of the folk have 3D printers and i just checked and see there's one in Nottingham.
This may not be too far for you to drop in and ask for a favour.
Most printers use ABS ( strimmer wire) and providing you can bond this the panel, you may get good results

Pitchers would really help of course to get an idea of shape and dimensions,
but I've sometimes nipped to local shops to get a cheap, thick, plastic cutting board to carve things out of.

Edit found the project posts in S/A/T
https://www.bikechatforums.com/viewtopic.php?t=278824
No pics of upper insides of panels to see good/bad lugs
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[Suntan Sid]

Thanks for the replies.

My problem with replacing the, push fit, lug is I don't have the original, so I've got nothing work with or to base a homemade one on. Also the PO has removed all traces of the broken, original lug.

In Del boys video the panels he's repairing are not the same type of plastic I've got, mine are the motox type, soft, bendy stuff, does that make a difference?
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[bikenut]

https://i1380.photobucket.com/albums/ah172/frankenbikestien/IMG_3542_zps74kifqdh.jpg

this stuff works well apparently.....not use it myself......
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[stirlinggaz]

[bugeye_bob]

what about a pipe clip, if you get the correct size it will just hold the corner secure to the frame, also wont require any special tools when you come to remove it again,

It may need a small bracket on the rear of the panel so the side panel is still level

https://www.gasproducts.co.uk/acatalog/ha868.jpg

[Teflon-Mike]

I've built up lugs by plastic welding before now;
https://i178.photobucket.com/albums/w269/teflons-torque/Little%20Dreams/PlasticsAndDecals/imag1542.jpg
Click pic for How-2.
My daughter, however is a fan of the hot-glue gun, and keeps telling me how brilliant they are and all you can do with one in the hope I'll buy one.. which may offer other possibilities.
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[Hop Along Biker]

Hi to everyone. I'm a new member and i came across this thread so I thought i'd let you know about a method i used. Go to your nearest car body repair shop or garage and ask nicely to look at the body panel fixings. Try and get all plastic or external panel fixings as they don't rust. There are quite a few different types of fixing. Most have a large head, some are push fit and some have a push in and screw fix (a bit like wall plugs) you can replace the screw with one that matches others on your bike so it blends in. If you don't mind them showing outside then check the one you have is the right size to fit the grommet on the bike drill a hole put the panel in position and push in the fixing, job done. I prefer the wall plug type so do the same and make sure it's the right size drill through push the fixing in then screw in to spread the lug wider (as i said you can change the screw to match your bike). If you want them hidden then simply check for fit and glue them on the inside of the panel (after removing the old lug bits) with either polyurethane glue (for decking) or two part epoxy. The polyurethane glue holds really well and will expand a bit to fill holes etc but once you open the tube it goes off in the tube after a few weeks so it isn't cheap unless you have a lot of friends who need to fix lugs and make a party of it!!. I was originally looking for a way of holding the seat up on a cb500 but after looking at the seat there was a perfect position for a bonnet stay type thing and it works perfectly so no more sore head or trapped fingers. Stay well and ride safe.
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Hop Along Biker