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I was verifying something on my bike after someone asked a question on the forum site and my fork guard broke as I was putting my cover back on.

This was actually good news for me as I was wondering what my next video was going to be about.

Funny how things just work out for you.

Click here to watch it.

Thanks
Paul
 

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Another good video Paul. Just an FYI; this is a common problem and I don't know why they moved away (cost cutting probably) from using chromed steel pieces for these that bolt on like they did for the Hammer and Kingpin which have these same forks. What I did when this happened was found some good used KP fork guards via ebay. They bolted right on.

Kewlmetal and others, maybe WD, has them as well in fancier versions.
 

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After having cracked a couple on different bikes, and repairing one, I went the route BBob posted. Opted for the jackpot/kingpin metal style that bolts to the forks. No more worries. :grin
 

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After being quoted $53(us) for one fork guard I too made a jig and super-glued mine....Unfortunately, it only worked for about 10mi until the top went flying down the road. The guard takes full wind pressure and sheer, flexing that tiny stem. Once its snapped the "glued" area will be the weak link and in short order will split apart.
I bit the bullet and ordered the Kuryakyn lower fork covers which come with a much more robust guard.
http://www.kuryakyn.com/products/4671/lower-fork-covers
 

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Great video Paul.
I broke mine the same way. Then tried gluing it with an epoxy for plastics byJB weld. But even after it was completely cured for a few days it was still weak and broke again while I was testing it for strength. Maybe a different glue would have been a better choice.

In my case I decided to reinforce it. I drilled a slightly oversize hole in each of the two pieces and inserted a small ringed paneling nail that I cut the head off of first. The hole is large enough to allow for the misalignment of the two holes. It is very hard if not impossible to get them to match up by eye but once filled with epoxy it should not matter if it is oversize or not.
When I did actually re glue it I first removed all the old glue and then packed the holes full of glue with a toothpick as well as separately filling the grooves in the nail with glue. When put together the excess glue from the hole was more than enough for the gap in the parts.

There are a couple of pictures below.
The way you held it during gluing is brilliant. Very nice. I had a heck of a time and I wish I had been that resourceful. I wish I had your video as a guide when I was doing it..
Anyone doing this should pay close attention and plan for the clamping ahead of time or you will have a terrible time getting a successful repair.

Not trying to hijack your thread. I too was going to start a thread on this and had the pictures so I thought I would throw them up here so that everything is grouped in the same place.
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Paul, what brand of super glue did you use? I couldn't make it out on the video.
 
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