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Rear shock stud end repair

Discussion in 'XJ DIY How-To Instructions' started by hogfiddles, Jun 9, 2015.

  1. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    My 650rj has a case of broken shock mount threads. A Previous Owner had snapped off the threaded parts of the upper shock mounts on both sides. His solution to keep the shocks from coming off was to weld them in place. Needless to say, now they couldn't pivot, plus they were actually weaker as the top rings were compromised.

    It took some time to figure out the solution. I wanted to stay as original as possible, maintain strength, and use factory equipment. The studs are no longer available, and I was not a out to try extracting ones from another frame, and then have to extract these, and still have to weld ones I to the holes.

    So, here's my fix-- for those of you who have similar issues, I can now supply you with these parts!!

    I let the pics speak for themselves, other than captions:


    ---Here we go
    Starting time
    image.jpg
    The problem
    image.jpg
    image.jpg
    Grind threads flush to stud
    image.jpg
    Center punch
    image.jpg
     
  2. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Step through drill bit sizes until desired hole is drilled

    image.jpg
    Tap the hole-- I used a regular tap, then a "bottoming tap" (shown)
    image.jpg
    The magic part!!
    image.jpg
    Installed with a couple locked nuts to torque it into place. Use RED locktite
    image.jpg
    All better
    image.jpg
     
  3. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Add the washer, standing handle, acorn nut
    image.jpg
    Look at the clock-- only one hour!!
    image.jpg

    The only things I used: hearing protection/eye protection, grinder and dremel, center punch, drill and bits, taps, wrenches, and red locktite.

    If anyone needs new ends for doing this project, contact me and I can have a set made for you!

    Dave Fox
     
  4. bubba650

    bubba650 Member

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    Great write up and good work! A++
     
  5. MattiThundrrr

    MattiThundrrr Not a guru

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    Ok, pictures make this perfectly clear. I get it now, but I still have 2 questions.
    1. How did you ensure that the hole you drilled was going in straight on,
    2. How many sissy bars do you have hanging on the wall there?
    The legend of your parts hoard grows...
     
  6. k-moe

    k-moe Pie, Bacon, Burbon. Moderator Premium Member

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    This is one way. [​IMG]

    The V shaped sliding part is a tool to find the center of any round stock. Ther are other types of center-finders, and some are pretty easy to make at home.
     
  7. MattiThundrrr

    MattiThundrrr Not a guru

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    That is a cool square. A lot of these fabricating tools are very new to me. Finding the center I get, but I still can't visualize what Dave would be doing to ensure that the hole goes in straight. There is not much there to place the square against, and a bunch of obstacles around it too. I don't have any real need for this info, my shock mounts are fine. However, since I am new to this, I want to learn as much as I can from others, so when a problem arises, I'll be ready! Someday, I'll have to learn about the electrical stuff too. I read the posts, but my eyes glaze over and my mind wanders... Thanks to all who have taught me!
     
  8. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Well..... I drill slowly and carefully--- I stop and check every several seconds carefully to make sure the drill is staying in a straight line from the side, and I can easily see if it stays in a straight line from the top.

    In short, if | and __ are straight, then the + will be straight.

    How did I make sure it was centered? I used my ruler and marked halfway, both horizontal center line and vertical center line.
     
  9. BaldWonder

    BaldWonder Innocent Bystander

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    Nicely done, Dave. This makes a lot more sense than your other, picture-less post that preceded this one, but what in the holy hell is that thing? (And don't say it's magic!)
     
    Last edited: Jun 10, 2015
  10. BaldWonder

    BaldWonder Innocent Bystander

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    Actually, looking at it more now: is it just a regular threaded rod that got lathed to a narrower diameter on one end, then tapped/died to the desired thread?
    I realize you may have explained that in the other post already, but I'm too forgetful and too lazy to find your post and re-read.
     
  11. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Yes, but go to your Local hardware store and ask for a step-stud that is:
    M10x1.25px14mm/m8x1.25px8mm and They will have no clue, tell you it's a wrong size, and tell you it's not available, and it's the wrong one, or it'll have to be custom-made, etc...
     
    Last edited: Jun 10, 2015
  12. PuskRat

    PuskRat New Member

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    I like that. Clean. Quick (relatively) and non-destructive (i.e. un-doable)
     
  13. AliMac

    AliMac New Member

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    Excellent solution - very helpful write up - many thanks
     
  14. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Thanks!hopefully it helps someone:)
     
  15. Franz

    Franz Active Member

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    Great repair Hogfiddles.
     
  16. kboehringer

    kboehringer Active Member

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    Very Very Nice Repair.... Great work!!!

    Every time I THINK I've seen the stupidest backyard repair, I get to see yet another. The P.O.'s welding that shock is definitely in my top ten of dumb arse repairs I've seen on these old bikes.
     
  17. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Thanks!!
    Yeah, I wish I had taken a close-up of the shock while it was still welded on the post! I do have a couple pics of it when first got it.... I'll have to see if its visible on those----
     
  18. MattiThundrrr

    MattiThundrrr Not a guru

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    I await the results...
     
  19. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    ;)
     
  20. Paul Howells

    Paul Howells Active Member

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    A thing of beauty!
     

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