Side panel idea

Great idea . I bought a couple of the 2" round amazing magnets to stick to the bottom of my oil filters and they worked good until I discovered that Kuryakyn makes a magnet just for the bottim of oil filters . The amazing magnets should work for the side covers , they have tremendous power .

Jack

Great Idea Lamont!

The paint on my side covers has been buggered-up where the fasteners hold them on from week one! It has looked like **** and frustrated me for quite a while. So far, the solution has been to use larger and larger washers on the fasteners to cover-up the bad paint. I don't know what looks worse, the bad paint or the huge washers!?!?!

If I were buying a new Boss Hoss, I would definitely try your idea and order the bike with the side panels undrilled if at all possible.

Bill

Bill , do you have rubber washers under the steel washers ? I have been using sink fauset seal washers under a chrome washer and they don't seem to mar the paint at all .

Jack

Don't know how different the 99 frames are but I got my panels in and it's going to take some bolts to hold these in place. :roll: These don't fit that great and I'm afraid that the magnets are not going to work because I have to do some pulling on them to get them to fit right. So what is the hot set up for bolts?

Jack,
We've gone to larger and larger and larger rubber washers trying to cover up the bad paint.

I guess I have to send the panels back to the painter to be touched up, but I haven't done it yet because I don't trust that the same problem won't happen again.

I see this problem on alot of Boss Hoss's, but I also see many without this problem. I would like to know what those guys are doing, you included Jack, to keep the paint from buckling up under those rubber washers. Is it a matter of allowing the paint to cure for a longer period of time or not tightening the bolts up at all?

Maybe the trick would be for the factory to put the teflon-type lock nuts in the frame tabs so when you screw the panel cover bolts in place you don't have to tighten them to keep them from backing out?

Bill

Lamont,
I'm using the 11 piece side cover screw set. Chopper city has them on their website, but I'm sure Mountain has them also. They have a rubber washer on the screw shaft, and the head of the screw is larger in diameter than the washer, so you don't see the washer unless you're looking for it. Does a good job of protecting the paint, and best of all, you don't need tools to screw them in or out. ......Don

http://www.choppercity.com/IMAGES/ecomI ... covers.jpg

Thanks, I'll give Mountain a call.

Boss Man said:

Lamont,
I'm using the 11 piece side cover screw set. Chopper city has them on their website, but I'm sure Mountain has them also. They have a rubber washer on the screw shaft, and the head of the screw is larger in diameter than the washer, so you don't see the washer unless you're looking for it. Does a good job of protecting the paint, and best of all, you don't need tools to screw them in or out. ......Don

http://www.choppercity.com/IMAGES/ecomI ... covers.jpg

Click to expand...

Lamont , When I first tried the late model side covers on my 2000 they didn't seem to fit that well on mine either and I remember I tried heating them with a heat gun and was able to reshape them somewhat . I would heat them up where I wanted to reshape them and when I got them forced to about where I wanted them I would have to hold them there and run cold water on them or the would go right back the shape the were almost like they has a memory . Now they fit very well I think . I have 4 screws holding them on .

Bill , the sink fauset washers I use on my side covers are about I/8" thick x 3/4" dia. and I use a 1/4 " -20 chrome button head screw with a 1/4 " x 3/4" chrome washer and rubber washers are very plyable and so far haven't screwed up my paint .

Jack

Bill,

It took 6 months for my paint to cure enough so that the original screws didn't "warp" it around the holes from the rubber washers.

Had to repaint my side covers and seat pan and the second time I let it sit for 3 months before I reinstalled. In addition I use the screw kit from Marv, which are slight under size and do not need to be tightened so much because you can check them by hand. This time around no twisting of the paint :lol: And I don't need a tool to remove the panels.

Tim

side covers

I been haveing luck with velcro 3/4 wide back side sticky clean good with carb cleaner if it is cold preheat with hair dryer cut to fit and your done.

Don,
Are those screws 1/4"-20 thread and how much were they for a set . They are nice but if I were to make a set I would knurl the O.D.

Jack

Jack
They are 1/4 20 thread. They come with a plastic tool about the size of a 3/4 shallow socket you can easily carry with you but finger tight works well. The way they are made knurling is not needed unless it is just for looks.

Jack,
1/4-20 is right. I got mine from Stamford BH. Somewhere around $40 or so. They have smooth or with ridges. I got smooth cause I liked the look. You can tighten them up pretty good by hand. I've never had one loosen up on me. The only thing is I had to run a die down some of the screws, due to some chrome residue in the threads. Other than that, I think they're the cats meow. No more having to dig out an allen wrench :wink: .....D

I'll give that a try. Thanks

HogV8 said:

Lamont , When I first tried the late model side covers on my 2000 they didn't seem to fit that well on mine either and I remember I tried heating them with a heat gun and was able to reshape them somewhat . I would heat them up where I wanted to reshape them and when I got them forced to about where I wanted them I would have to hold them there and run cold water on them or the would go right back the shape the were almost like they has a memory . Now they fit very well I think . I have 4 screws holding them on .

Bill , the sink fauset washers I use on my side covers are about I/8" thick x 3/4" dia. and I use a 1/4 " -20 chrome button head screw with a 1/4 " x 3/4" chrome washer and rubber washers are very plyable and so far haven't screwed up my paint .

Jack

Click to expand...

Thanks Guys , I think I'll order a set but if I was still managing the machine shop and had access to a lathe they would be simple to make out of S.S. and polish . Oh well , I guess I'll have spend some of my retirement money .

Lamont , just be careful with the heat gun . I blistered the plastic in a couple of spots slightly but of course that was before they were painted .

Good luck,
Jack

TJzz4 ,

The tool you mentioned to tighten the side cover screws , how does it work ? From what I heard they make two types , a smooth head and a knurled or grooved head . How would any kind of tool work with either ?Or do you have something different than Don's picture ?

Thanks ,
Jack

I might be missing the boat here but.....

Why not make a set of side covers out of fiberglass. Make your form using chicken wire, then lay the glass on top. Finally fiberglass onto the back side of the side panels the same type of metal clip-on that comes with the 2000 year BH. And mount it to the frame. Am I missing something in this picture?
Milos

This may be hard to descibe but here is what I did for a sanitary and strong installation for my 2000 sidecovers. Left the lower frame clip on. Epoxied a tab on the inside of the rear of the cover through which I drilled a hole, tapped the rear down tube of the frame and it bolts on. Also fabricated a heavy hook to go under the top frame rail which is epoxied to the inside of the covers. No bolts through the covers and is very strong. Easy on-off also. Will try to post pics..Joe