cracked vario top box

[steveh]

I got hit a while back by a car and my top case (bmw vario) took the brunt of the impact and I think this must of caused some initial damage.

Last week my top box came off in town!, on closer inspection the bottom of the case has cracked all around the bottom where the case attaches to the locking plate (the 2 rear lugs are all fine).

A bungy cord will hold the box on tight however I wanted to see if anyone has used any epoxy glue to at least prevent the cracks in the case getting any worse and if so which type?

 

[littleredrooster]

This was a common problem with the early cases. They would crack extensively around the mounting area and fall off. BMW replaced loads back in 2004, IIRC

I do believe that some folk repaired them with glass mat, metal plates and resin to good effect, though.

 

[VAL. H.]

I got hit a while back by a car and my top case (bmw vario) took the brunt of the impact and I think this must of caused some initial damage.

Last week my top box came off in town!, on closer inspection the bottom of the case has cracked all around the bottom where the case attaches to the locking plate (the 2 rear lugs are all fine).

A bungy cord will hold the box on tight however I wanted to see if anyone has used any epoxy glue to at least prevent the cracks in the case getting any worse and if so which type?

This was a common problem with the early cases. They would crack extensively around the mounting area and fall off. BMW replaced loads back in 2004, IIRC

I do believe that some folk repaired them with glass mat, metal plates and resin to good effect, though.

Blimy! I'd forgotten this one. I had mine replaced it late 2005.

Have a word with your local BW dealer. I think you can get the bottom part of the case on it's own.


Val.

 

[Pathologic]

Me too

Had a similar minor prang with a biscuit tin that left one panier cracked around the mount. Didn't see it at the tme. Tried various glues to no effect. Eventually used some car dent filler from Halfrauds and then bolted through the repair for good measure. Only done about 500 miles but so far so good.

Id take some pictures, but the bike is 150 miles from my current location.

Hope you get it fixed.

Regards,

Path.

 

[GrinningGSer]

As others have said, there was an issue with older, circa 2005, vario top boxes. The original ones cracked without any need for accidents.
They were later modified to stop the cracking:

I didnt keep my bike for long enough afterwards so I dont know if the mod was successful.

 

[Popell]

are they still honouring replacements, I found a crack earlier this year - was wondering what I was going to do with this

 

[The Nutter]

are they still honouring replacements, I found a crack earlier this year - was wondering what I was going to do with this

Noticed a crack in mine after the bike was about 2-3 years old. Got a flat 'no' on a replacement so I used a strip of steel and 2 stainless bolts to reinforce a soldering iron plastic weld job. Lasted another 2 years on that bike and now on my 2010, so far so good.

 

[Jumpjim]

You can buy parts of the Vario panniers from BMW dealers.

I had one of the plastic hooks on the side cases break off after a small prang and tried plastic welding but it wasn't strong enough.

After a suggestion from a helpful tosser I ordered a whole new back panel for my offside Vario for about £50 and then rebuilt the pannier on it which was relatively easy.

Just a thought....