Cyclops side panel pin repair.

[Sam Mac]

Thought I’d share how I repair the common side panel broken pins on the Cyclops.
1st I drill the hole in the center of the old pin all the way through with a 7/32” drill
2nd I grind any remaining remnants of the old pin flush
3rd I use a ¼” X 2” hanger bolt double nutted so that I can thread it into the hole
4th I use 3M structural adhesive to secure the bolts in the hole.
5th I use a piece of 5/16” fuel hose over the bolt to fit the hole in the grill and protect it from wear.
6th I use a washer and a wing nut to secure the panel to the grill. You can remove the black grill to get at
the lower nut when you install the side panel.

[Frank1541]

Sam Mac,

Thanks, I am at the point where I need to do this and your method looks great. I never thought of using the fuel hose, but I will now.

[Gary C]

Sam, do you run a tap through or just thread the stud in?

[Sam Mac]

One end of the hanger bolt has a wood screw thread so you just screw it in after drilling with a 7/32" drill bit. I stuffed some of the glue into the hole and put some on the threads before I screw it into hole.

[bugeye]

I used a similar repair using the same threaded stud. It has been holding for more than ten years. I also removed the pin, but did not use epoxy. I carefully heated the stud with a torch and carefully threaded into the panel plastic. Took a few heat and thread tries so as to not overheat the plastic. I use a fender washer on the inside to spread the load on the grill support.