It's worth logging on tonight! Roadcouch, what a great idea with using the phone. Ricz, what a great bit of lateral thinking to apply it to the fridge; I've lost sleep thinking about that little light. I live off the grid on stand alone solar so I do worry about every bit of reducible electrical consumption. Solar electricity is expensive!
Back to the latch, I had to do something like this. My first idea that there was a problem was when the die cast alloy loop on the latch wore completely through and the lid flipped open at 130 kph. Wish I'd known about the paperclip preventative.
It was still under warranty, but the Brisbane Vic shop said they couldn't supply a lock barrel to match an existing key if they replaced the latch. Having two keys didn't appeal, and my hillbilly sense of thrift was offended at replacing all 7 locks.
Vinish, I'll post a drawing soon, but roughly, I cut off a length of square section tube, sawed one side completely off, then profiled two sides to match the tapered profile of the original alloy loop, leaving some protruding "ears" at the thick end.
Then on the third side, I drilled 2 holes, sawed and filed between them to make a slot the same size as the broken off original., filed and sanded it all smooth.
I then spread the protruding "ears" slightly to make a tight fit on the remaining latch body, then glued them on with the metal filled epoxy. A little bit over an hours work once you start cutting metal, with a lot of hours thinking it over first.
You wouldn't do it if it hadn't all broken, much easier just to adjust the wire loop on the bag body to prevent the wear, maybe add the suggested paperclip, but I wasn't a member of this forum then.
So far it's lasted well, the eventual failure will probably be the epoxy, but hey, I still have the tubes of it!
2013 Hard Ball
Stage 1 mufflers
K&N air filter
Rubber air dam removed
Whole lot of extra cable ties, shrinkwrap and tape on loom
Hard chrome spherical joints in back
Hammer front guard
Wide Glide fork boots