Author Topic: How to Fix Top Box Lid Stays (Read 7639 times)

Snigdog · « **on:** March 06, 2015, 07:37:51 PM »

I don't know how many have had problems with the string stays that hold the top box in the open position........I certainly have.
The string ones that were on the bike wore out/broke and I tried various things to replace them, twine, electrical wire etc. none of which worked particularly well.
I found it hard to judge to the correct length on both sides and then tie off around the little bobbin thingies.

Then I tried cable ties (see picture). They have been brilliant, easy to install and what's more don't get caught between the two halves.
Get a largish cable tie, sit the lid about where you want it and mark the positions of the bobbins. Cut a lengthwise slit in the tie on the mark at each end and then trim the tie to an appropriate overall length.
Fit by pushing the tie where it is slit over the bobbins...you may have to lengthen the slit a little to get it over.
Voila...fixed
sD

Abe · « **Reply #1 on:** March 06, 2015, 07:59:56 PM »

Nice work there Snigdog

Cheap and replaceable, most of all, it works

tj189 · « **Reply #2 on:** March 06, 2015, 09:49:57 PM »

Clever

thanks for posting it up

Gadget · « **Reply #3 on:** March 07, 2015, 07:05:57 AM »

Aussieboy · « **Reply #4 on:** March 07, 2015, 09:05:07 AM »

Great idea thanks for posting. I got a few sets of the originals under warranty. My fix was to glue the ends where they are spliced with super glue and that has seen the last set work for 4 years - worth a try if your originals haven't pulled apart yet.

A2Z · « **Reply #5 on:** June 02, 2016, 05:54:20 PM »

Brilliant. Just the fix I needed.

Sicman · « **Reply #6 on:** June 02, 2016, 06:02:38 PM »

West Aussie Glen · « **Reply #7 on:** June 02, 2016, 10:14:12 PM »

I just left mine off but you need to make sure the lid is locked when removing the top box from the bike.

BigTed · « **Reply #8 on:** June 03, 2016, 09:59:45 AM »

I'm sure I got this idea from OzSToc, possibly during a meet if not on the site...

Pop into a BCF and grab a bag of fishing wire traces. They cost a few bucks and last forever. You can buy them with just loops at each end, or with swivels that can be removed with write cutters.
I think mine were 13cm in length.

https://www.google.com.au/search?q=fishing+trace+wire&client=ms-android-google&biw=412&bih=619&prmd=isvn&source=lnms&tbm=isch&sa=X&ved=0ahUKEwivye-CrorNAhUHopQKHTggAN4Q_AUIBigB#imgrc=MIaD4TGBAJqDfM%3A

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A2Z · « **Reply #9 on:** June 03, 2016, 10:18:03 AM »

Another problem I have with this is that the threads on the box where you screw it into are stripped. Any fix for this?

ST2UP · « **Reply #10 on:** June 03, 2016, 11:42:07 AM »

Quote from: A2Z on June 03, 2016, 10:18:03 AM

Another problem I have with this is that the threads on the box where you screw it into are stripped. Any fix for this?

Larger diameter screw (BUT NOT LONGER).....

Fill screw hole with supa glue or similar and re-drill after its set

Biggles · « **Reply #11 on:** June 03, 2016, 12:16:02 PM »

Quote from: ST2UP on June 03, 2016, 11:42:07 AM

Larger diameter screw (BUT NOT LONGER).....

Fill screw hole with supa glue or similar and re-drill after its set

Not superglue. It basically has no gap-filling capacity. JB-Weld or other hard-setting epoxy is the go. I like Kneadit- behaves like putty and sets like rock and can be drilled and tapped. Comes in white for wood or black for metal.

ruSTynutz · « **Reply #12 on:** November 25, 2019, 04:31:22 PM »

I decided to make some "stays" for my top box as the originals were missing when I bought my ST...

I ended up buying a length of 3.6mm bead chain. Luckily it came with 4 loop ends which worked out perfect!

The chain is rated at 6kg working load so I figured that should be fine considering the top box lid doesn't weigh much.
I then got some 4mm flexible tubing to slide over the chain so the balls don't catch on anything and to also "encourage" the stays to fold inside the top box when closing...

I just used a few washers & a nut to "pack" the mounts so the screws didn't pop through where they shouldn't.

It all works perfectly!

Now, if I can source some replacement "loop ends" I just might have to knock out a few more as I have a stack of chain & tubing left over...

Biggles · « **Reply #13 on:** November 25, 2019, 11:18:29 PM »

That's a very elegant fix. I'm sure there would be plenty of people on the forum who would gladly pay bux for a pair if you can source "loop ends".
The joiners they sell for the chains that operate blinds may do the trick. You could check suppliers because I know they sell the bits apart from the blinds.

ruSTynutz · « **Reply #14 on:** November 26, 2019, 08:51:25 AM »

Thanks Biggles!

I managed to source some off ebay last night so I ended up ordering 4 packs which will be enough to make up four sets...

ruSTynutz · « **Reply #15 on:** December 05, 2020, 04:30:19 PM »

Well, I decided to replace my "stays" as, while the bead chain was easily strong enough, the "loop ends" weren't...
Twice now I've had a loop end spring apart just enough to let the ball chain rip out.
This has happened when there's been a strong wind pulling on the lid while open.

Anyhow, I decided to come up with a much stronger "fix"...

I ended up using some 2mm stainless steel cable wrapped around the original red restraint mounts and then "fastened" with a 2mm Stainless Steel Swage.
As with my previous "ball" restraints, I ran the cable through some flexible tubing, mainly so the cable wouldn't rub (& possibly damage) the edge of the top box lid when open.

Gadget · « **Reply #16 on:** December 05, 2020, 06:50:55 PM »

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West Aussie Glen · « **Reply #17 on:** December 05, 2020, 10:10:41 PM »

I have just left mine off. Trick is not to pick it up by the handle when off the bike and you haven't locked the lid closed.

richo · « **Reply #18 on:** December 06, 2020, 07:00:27 AM »

. Looks good. I will have to borrow this one

ruSTynutz · « **Reply #19 on:** December 06, 2020, 09:57:46 AM »

Go for it, Richo...

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Author Topic: How to Fix Top Box Lid Stays (Read 7639 times)