DIY: Crashbar stud mounts step-by-step

[Nut Clutch]

Here is the set screws I ordered from Mcmaster a while ago:

http://www.mcmaster.com/#catalog/118/3076/=i3anj9

92015A151

I got the 50 mm studs, but I also drilled and tapped the holes a bit deeper because I stripped the threads on one side. I think I was able to drill and tap an additional 10mm. Can't remember if I used a bottoming tap.

[jconly]

Wondering if anyone may happen to know how deep the screws thread in?
I'm going to go the stud route, but my threads are already mangled so I'd like to helicoil first.

Wondering what size I would need. M8 @ 1.25 pitch, but how long....

If anyone happens to know off the top of their head, that would be awesome.

Thanks

[bikyto]

Originally Posted by jconly

Wondering if anyone may happen to know how deep the screws thread in?
I'm going to go the stud route, but my threads are already mangled so I'd like to helicoil first.

Wondering what size I would need. M8 @ 1.25 pitch, but how long....

If anyone happens to know off the top of their head, that would be awesome.

Thanks

14mm long are the factory bolts (thread).

[jconly]

Thanks, not that I don't believe you though, but the parts diagram does show that the standard bolt (not that for the guards) is 16mm long. Do they factor the head into these figures? I didn't think so?

Due to the spacers, the ones supplied with the guards must be longer than in the OEM diagram though.

Regardless, I'm more interested in the depth of the threads on the mount... how much of the bolt is actually screwing in. I'm guessing it's about 10mm of thread? Leaving 30mm exposed (with the 40mm recommendation) for the cover, spacer, bar, wash and nut.

Also wondering where I can find a diagram of all the hardware included for the crash bars. Also looking for a bolt length figure for the lower tank mounts.

[bikyto]

I have 30mm exposed on the right (facing the bike). And 25 on the left.
Keep in mind that you will not be able to remove the cross race once the studs are in unless you unbolt the header. The shorter stud allows me to loosen up the header bolts without having to remove it and wiggle the brace out.

[jconly]

Good to know, thanks.
Not sure I was planing on permanently affixing the studs. Was thinking I would just torque them in with medium loctite.

So with 25mm and 30mm exposed, do you remember what the actually length studs you used. 35 and 40mm?

I'm beginning to think its 10mm the bolt threads in to the mount. Thinking I'll be going with the M8 x 10 helicoil.

[Phil in K.C.]

Rule of thumb is you reach max strength on a bolt at 1 and one half times the dia. of the bolt...so it really does not matter how deep the hole is...as long as it is 1 1/2 times deeper that the dia.

[jconly]

Originally Posted by Phil in K.C.

Rule of thumb is you reach max strength on a bolt at 1 and one half times the dia. of the bolt...so it really does not matter how deep the whole is...as long as it is 1 1/2 times deeper that the dia.

This is invaluable to me.
Going to go for 12 mm and call it a day.

Thank you both!

[gefr]

due to galvanic effect as I saw some people in here mentioned.

[FakeName]

Originally Posted by Jabba

and I found these online after a ton of digging. Thought I'd share-

http://www.fastenal.com/web/products...X2580040A20000

Thank you for this. Saved me a ton of digging, and worked perfectly. Skipped the entire wrestle-with-the-crashbars experience and did it the first time I had them off.

Easy-peasy.

Yes, I used two nuts.

[Skyclad]

Another change that I made is to get rid of the threaded clips for the lower tank mounts. That was the most difficult bolt to get lined up for me. I finally got tired of it and just use a shouldered nut there now. Easy peasy to put the crash bars back on now

[lowes48]

Went to the local Fastenal and was able to score some M8 studs that are 30mm in length. Do you guys think these will be long enough?

[Bowser]

Originally Posted by gefr

due to galvanic effect as I saw some people in here mentioned.

No problem, use some zinc chromate paste, such as boat owners do to prevent saltwater and galvanic issues, I have used it for years on my GS and never had any problems with ali and stainless,

[FakeName]

Originally Posted by lowes48

Went to the local Fastenal and was able to score some M8 studs that are 30mm in length. Do you guys think these will be long enough?

Definitely.

Maybe.

Possibly.

I wouldn't. The only way to make them work is to reduce the amount of stud in the boss. Given I'm prone to using my crashbars, that's a lot of force.

Just order the ones you need from Fastenal. They can bring them in from another store, or you can order them online.