Cracked Turn Signal Bracket

[CutterBill]

I just want to bring this to the attention of anyone who might have a hard luggage system mounted on their FJ. This is the rear turn signal bracket. This bracket is used by various luggage rack makers to support most of the weight of the loaded bags. Problem is, this bracket was designed to hold a 6-ounce turn signal, not a 30-pound suitcase. So it cracks.

I have a '92 FJ with the Hepco & Becker system, and a '93 FJ with the Givi Wingrack system, and they both had this cracking problem. Take a good look at your brackets. It they are cracked, you really should get it fixed before your hard case falls off in the middle of trip. In the dark. And it's raining...

So here is how I fixed both bikes. First, a photo of the cracked bracket...

[CutterBill]

I don't think that simply welding up the crack would last very long. That is just thick sheet metal and it is being overloaded. So I made some brackets on my mill...

[CutterBill]

Sorry, I didn't get a photo with the original bracket removed. But I just cut off the whole tab, then ground it smooth. Of course I sanded off all the powdercoat in that area. Then I welded the brackets in place, along both sides and the top...

[CutterBill]

A little primer and paint, and Bob's your uncle. Easy. (sorry, I don't know how to post multiple photos in one post.)

[aj52]

Those brackets on the ABS also teared off.
Purchased it like that 5 year ago. PO did not fixed it very nicely.I never thought the rack caused it.
This new brackets of yours gave my a good idea how to fix mine.
I moved the rack over to the other FJ in the week,for the up and coming rally end of March.

Thanks for the warning,better "fix" those tabs on the other FJ as well,before it shear.

Hannes

[X-Ray]

What a fantastic fix! I have one to repair now, although I only have an arc welder, so I doubt the finished weld will be as neat as yours

[ZOA NOM]

A little primer and paint, and Bob's your uncle. Easy. (sorry, I don't know how to post multiple photos in one post.)

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