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DIY Better System Case Hinges

 
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Flying Duck
PsyKotic Waterfowl


Joined: 27 Jan 2005
Posts: 9892
Location: Bumf***, WA

PostPosted: Wed Apr 14, 2021 8:59 am    Post subject: DIY Better System Case Hinges Reply with quote

There are probably other sources but I get my aluminum piano hinges from McMaster-Carr: https://www.mcmaster.com/1581A281/

For fabbing metal stuff at home you can use a metal cut-off blade in your table saw. You can find one of these at your local hardware store, Harbor Freight or Amazon:
https://www.amazon.com/DeWalt-DW8005-General-Purpose-Metal/dp/B00004YMCI/ref=sr_1_1?dchild=1&keywords=B00004YMCI&qid=1618404878&sr=8-1


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93 LT (x2)
94 RS
86-97 K75F(K75/100/1100 Frankenbrick)
86 K75C w/paralever, hi perf cams,TURBO!
91 & 92 K75Ss
91 K1
86 custom K100
14 WR250R
IBA #17739 (SS1K, BBG, 50CC)
Buy parts HERE


Last edited by Flying Duck on Wed Apr 14, 2021 11:47 am; edited 1 time in total
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Sonu
Flying Brick Rider


Joined: 15 Jan 2004
Posts: 369
Location: San Jose, CA

PostPosted: Wed Apr 14, 2021 10:30 am    Post subject: Reply with quote

Most excellent Drake

I'm impressed by your tireless energy to keep perfecting this old bike (even though you have newer toys in your stable)

Cheers,

Sanjiv
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1997 K1100LT "Ziggy" _GarminGPS_Corbin saddle_K Guards _Hyperlights_Fog lights_Eastern Beaver Relays_Cee Bailey_4"speakers_Michelin PR4's_MoS2_Spiegler lines_TPMS_VDO
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Flying Duck
PsyKotic Waterfowl


Joined: 27 Jan 2005
Posts: 9892
Location: Bumf***, WA

PostPosted: Wed Apr 14, 2021 12:10 pm    Post subject: Reply with quote

Sonu wrote:
Most excellent Drake

I'm impressed by your tireless energy to keep perfecting this old bike ea(even though you have newer toys in your stable)

Cheers,

Sanjiv


Thanks. It actually took me a few iterations to come up with this. My first attempts worked but had issues. For example, on the first set I didn't bother to round off the corners. When I'd throw the cases on the other bed in motel rooms the square corners would snag on the bedspread when I picked the cases up. I also used seven bolts per side but later decided that was overkill and that you really only need four bolts per side.

Once I came up with the final iteration above, I decided to document it so that it would be easier for me to replicate in the future.
_________________
93 LT (x2)
94 RS
86-97 K75F(K75/100/1100 Frankenbrick)
86 K75C w/paralever, hi perf cams,TURBO!
91 & 92 K75Ss
91 K1
86 custom K100
14 WR250R
IBA #17739 (SS1K, BBG, 50CC)
Buy parts HERE
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Jim
Site Admin


Joined: 17 May 2003
Posts: 3805
Location: WHERETHEFUNNEVERENDS

PostPosted: Wed Apr 14, 2021 11:42 pm    Post subject: Reply with quote

Good job! Thank you! Those plastic hinges are a pain to change.

Hope BMW doesn't go out of business because of lost sales of system case hinges... Laughing
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Jim
1997 K1100LTSE 94,000 - has gremlins!
1995 R100RT Classic 16,650 crashed!
1992 K75RTP 46,000 - RUNNING - at last!
1992 R100R 24,000 - FOR SALE

"We shall not all die, but we shall all be changed."
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Flying Duck
PsyKotic Waterfowl


Joined: 27 Jan 2005
Posts: 9892
Location: Bumf***, WA

PostPosted: Thu Apr 15, 2021 6:38 am    Post subject: Reply with quote

Jim wrote:
Good job! Thank you! Those plastic hinges are a pain to change.

Hope BMW doesn't go out of business because of lost sales of system case hinges... Laughing


One thing I learned (the hard way) on my first long K tour is that worn out broken system case hinges can be temporarily repaired with a couple of layers of duct tape until you get home.
_________________
93 LT (x2)
94 RS
86-97 K75F(K75/100/1100 Frankenbrick)
86 K75C w/paralever, hi perf cams,TURBO!
91 & 92 K75Ss
91 K1
86 custom K100
14 WR250R
IBA #17739 (SS1K, BBG, 50CC)
Buy parts HERE
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