As Don MacLean said in his hit single American Pie…

“A long, long time ago, I can still remember…”

As for me… I can still remember being a project engineer for a certain custom commercial millwork company.  We did lots of swanky woodwork for companies like Whole Foods Markets and Barnes and Noble book stores.  In one of the many aspects of this business, we would create drawings and then contract out all sorts of acrylic work.  Mostly those bin systems used to sell coffee, nuts, breakfast cereal and other bulk dry goods at these same locations.  There was an item we used often called a “living hinge.” Wikipedia tells me  a living hinge was first observed in pigmented polyethylene by the Enjay Corpration, which is now part of Exxon/Mobil… blah, blah, blah… blah… blah,blah… blah…. 

“but that’s not important right now.”

The thing is… having recently purchased a GL1500 with broken side pockets and having heard horror stories concerning loosing one of these precious little babies on the highway,  I found myself thinking… “There has to be a solution for this!”   So…

“Pardon me, whilst I whup this out!”

My repair solution for broken side door packets on a Honda GL1500:



Materials:

  • 8 to 10 Inches of 1-1/2″ Living Hinge
    (I used USPlastics #44112)
  • 1/8″ pop rivets
  • Double sided tape
  • 150 grit sand paper (or similar)
  • Utility Knife
  • Duct tape
  • Denatured alcohol or a light-dry petrochemical like lacquer thinner
    (Alcohol preferred. You will have to be very careful with the thinner.)
  • A United States penny or similar coin.
  • Small Craft/Hobby Brush
  • Black Paint

Tools:

  • Loose hack saw blade or Dremel style rotary tool
  • Pop rivet gun
  • Ruler
  • Felt marker (Sharpie)
  • Heavy Scissors
  • Electric drill & 1/8″ drill

Prerequisite Skills:

  • Ability to read. (English)
  • The ability to comprehend what you read. (in English)
  • The ability to follow instructions and adapt them to you specific needs.
  • Basic dexterity with hand tools.
  • The ability to measure to within 1/32″ or 1mm.

Process:

This is the living hinge material.  The minimum purchase unit is about 5 feet long.

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1.  Measure and rough cut cut two pieces about XX inches (XX cm) long!

2. Using the sand paper and the utility knife dress the cut edges of the hinge material.


Remove The Seat3. Remove the seat handle and tape a rag in place to protect the saddlebag.


Cut Away Remaining Hinge Pins4. My hinge still had one of the pivot pins in place.  I had to cut this away using a loose hack saw blade.  (This was VERY difficult for me.)


Clean The Plastic With Alcohol5. Using a microfiber rag and denatured alcohol clean the area around the hinge thoroughly.  I think alcohol works well for this as it de-greases the plastic and leaves the surface clean and very dry.  I like microfiber cloth because it gets down into the texture of the plastic… providing for a good bond for the adhesive strips.


Add Two Strips Of Double Sticky Tape6. Apply two strips of double sided adhesive tape to the back side of the living hinge.  Trim to fit.


Snap The Door Back Into The Opening

7. Snap the pocket door into the opening and use two pennies as spacers at the top of the opening.


Press Hinge Firmly Into Place8. Remove the paper backing from the double sided tape and carefully position the gutter of the hinge is aligned along the center line of the lower gap of the pocket door.  Press hinge firmly into place.


Drill And Set Rivet9. Using the electric drill with the 1/8″ bit,  carefully drill through the hinge and the pocket door.

10. Carefully insert and set the pop rivet using the rivet tool.

11. Step back to admire your work.


Repeat For Remaining Rivets12. Repeat steps 9 through 11 using the TLAR method to align and center each rivet.
(TLAR=That Looks About Right!)


Paint The Rivets13. Apply a couple of thin coats of blackish paint to the rivets using the small craft brush.

14.  Repeat entire procedure for the other side.

15. Your pocket doors are now safe from the road gremlins.

 

One Response to Hatch Door Modification: 1988-2000 Honda GL1500 A,I & SE

  1. […] the forum and also found the following option to repair. Click on the link below to see tutorial. http://www.culleynet.com/cool-links/…-gl1500-ai-se/ Hope this helps. Gimpy __________________ Wish I had more time to […]