Broken CB77 tool box

akpasta · Post by **akpasta** » Wed Dec 21, 2016 5:46 pm

Hi Folks,

1964 CB77 and I noticed yesterday the side-cover mounts on my tool box have snapped off the tool box. Replacements on ebay that aren't also broken or covered in rust appear to cost $50-$120. Has anyone ever attempted a repair of this item? I'm not sure if it's steel or aluminum but my first thought was to get a piece of flat metal about 2"x3" and jb weld it to the inside of the tool box and mount, and use it kind of as a joint or something. Does that make sense? Anyone else have a repair to try?

Seems like the thin metal on the tool box is a recipe for broken side cover mounts.

pemdoc65 · Post by **pemdoc65** » Wed Dec 21, 2016 10:48 pm

I MIG welded mine back together, ground down the welds and repainted. They seem to be holding. A small plate welded to the backside of the mount (inside the box) would provide added strength. This is a pretty common problem. On one of my other bikes, I ran a bead of weld around the tab that mounts to the box before it had a chance to crack.

akpasta · Post by **akpasta** » Thu Dec 22, 2016 11:59 am

Unfortunately I do not weld.

Goodysnap · Post by **Goodysnap** » Fri Dec 23, 2016 9:16 am

akpasta wrote:Unfortunately I do not weld.

So take it to someone that does.

Mig welding is going to be the only worthwhile repair option for your situation. I suppose Brazing may work OK as well.

Tim Allman · Post by **Tim Allman** » Fri Dec 23, 2016 11:05 am

Goodysnap wrote:Mig welding is going to be the only worthwhile repair option for your situation. I suppose Brazing may work OK as well.

I had to have this repair done many years ago and brazing worked (and continues to work) well. Clearly this is a stress failure and the rather large amount of bronze used has likely spread the stress and reduced the strain on the sheet metal.

Goodysnap · Post by **Goodysnap** » Fri Dec 23, 2016 11:54 am

Tim Allman wrote:I had to have this repair done many years ago and brazing worked (and continues to work) well. Clearly this is a stress failure and the rather large amount of bronze used has likely spread the stress and reduced the strain on the sheet metal.

I agree that brazing does tend to work better on thinner metal repairs. That thin steel is difficult to work whichever you choose. If rusty even worse yet.