Mouse
Registered user
Well it's been a while since I posted a "DIY" thread, so here's my latest offering 
First - background: The bash plate (and optional engine bars) are attached to the bike in four places. The top point is a big bolt (10mm I think) through the front frame member, which is pretty strong. The other three points use 6mm bolts with rubber washers, one also to the front member, and the other two to rather frail "tabs" welded to the bottom section of the frame (under the sump).
Anyway a bit of over enthusiastic (and cack handed) rock climbing resulted in a large impact to the bottom of the bash plate, which cracked these little tabs clean off. I don't have a picture of the tabs, so sorry, you'll have to use your imagination.
Luckily (or just maybe it's designed that way
) the bottom section of the frame is just bolted on - its only function is to hold the bash plate and side stand, so you can just remove it for repair.
Here's the frame section with a new plate welded on in place of the puny tabs. The extra bit of metal is a holder for a couple of electrical plugs that live in that area, it used to be welded onto the frame directly but I had to grind it off and weld it back on top. No insults to the quality of the welding please, it wasn't me and it didn't cost anything
Here's the bash plate + engine bar assembly off the bike. This picture shows the two replacement lower mountings I'm going to use. They are rubber "cottom reels" very similar to the ones used to mount the bash plate on the R1200GS. The ones in the picture have a 6mm thread on each end.
I drilled a couple of holes in the new mounting plate, and here's how it all fits together. Well, the bash plate isn't mounted in this picture, so I could see if it all lined up.
And here's the view from underneath.
A quick coat of black Hammerite to make it all look pretty.
And finally, refit the sidestand and its switch, cable tie the wires to the little holder thingy. This pic shows the new mounts with the bash plate also in place. I used a large washer (like those you can see in this pic) either side of the bash plate because it has very large mounting holes (they are originally designed for the inadequate rubber mounts provided).
The only slight problem is that with all the washers, the bash plate and the engine bars in place on the lower thread of the new rubber mount, there wasn't room to use a nylock nut on the bottom. So a bit of threadlock and I'll keep an eye on it
First - background: The bash plate (and optional engine bars) are attached to the bike in four places. The top point is a big bolt (10mm I think) through the front frame member, which is pretty strong. The other three points use 6mm bolts with rubber washers, one also to the front member, and the other two to rather frail "tabs" welded to the bottom section of the frame (under the sump).
Anyway a bit of over enthusiastic (and cack handed) rock climbing resulted in a large impact to the bottom of the bash plate, which cracked these little tabs clean off. I don't have a picture of the tabs, so sorry, you'll have to use your imagination.
Luckily (or just maybe it's designed that way
) the bottom section of the frame is just bolted on - its only function is to hold the bash plate and side stand, so you can just remove it for repair.Here's the frame section with a new plate welded on in place of the puny tabs. The extra bit of metal is a holder for a couple of electrical plugs that live in that area, it used to be welded onto the frame directly but I had to grind it off and weld it back on top. No insults to the quality of the welding please, it wasn't me and it didn't cost anything
Here's the bash plate + engine bar assembly off the bike. This picture shows the two replacement lower mountings I'm going to use. They are rubber "cottom reels" very similar to the ones used to mount the bash plate on the R1200GS. The ones in the picture have a 6mm thread on each end.
I drilled a couple of holes in the new mounting plate, and here's how it all fits together. Well, the bash plate isn't mounted in this picture, so I could see if it all lined up.
And here's the view from underneath.
A quick coat of black Hammerite to make it all look pretty.
And finally, refit the sidestand and its switch, cable tie the wires to the little holder thingy. This pic shows the new mounts with the bash plate also in place. I used a large washer (like those you can see in this pic) either side of the bash plate because it has very large mounting holes (they are originally designed for the inadequate rubber mounts provided).
The only slight problem is that with all the washers, the bash plate and the engine bars in place on the lower thread of the new rubber mount, there wasn't room to use a nylock nut on the bottom. So a bit of threadlock and I'll keep an eye on it
