Breaking mudguard stays.

[mlplatt]

At about 2000 + miles the near side mudguard stays on my Sportster sheared. The break was at the flat bit where the bolts secure it to the wheel. This flat was then reinforced with double thickness and reattached. The strengthening modification was also made to the off side mudguard as I thought the fault was potentially dangerous and didn't want to risk a repetition.

Shortly afterwards David Siddal, who had kindly carried out the repair for me, had the same problem on his Sportster at around the same mileage.

Today, about 1,000 miles later, the near side mudguard again sheared, this time in two places on the round sections of the stay. Luckily the this happened when the car was practically stationary on slowing for a tee junction. The mudguard was thrown off and under the wheel. As I have a side light fitted on top of the mudguard it was still secured to the body by the wiring. Much clattering, the mudguard badly scarred and the light crushed but otherwise no harm done.

I think it could have been a lot worse in different circumstances.

Both David and I have mud flaps attached which doubtless add to the stress on the stays. On the other hand the mudguard itself is so short as to be quite ineffectual without them.

I am posting this firstly as a warning for other Sportster owners. And secondly as a plea for any suggestions. There seems little point in replacing like for like stays. Something stronger is needed without drastically increasing the unsprung weight. Preferably allowing the mudguard to be positioned further back obviating the need for mudflaps. Or perhaps fixing the mudguards to the body?

Any ideas welcome. In the meantime take care.

Regards,

Malcolm

[andy-rogers]

Re: Breaking mudguard stays.

Malcolm, how about attaching the mudguards to the chassis rather than wishbones - see photo. Obviously you'd need wheel clearance for suspension movement, and mudguards would not turn with wheels.

[Peterx]

Re: Breaking mudguard stays.

Malcolm,
sorry to hear about your wing stay incident. I know of two other Sportsters that this happened too.
I think Marlin did a free replacement re-call on the old wing stays that had hollow tube stays but I can't find a copy at the moment. Although your failure point sounds a bit different?
I suggest you contact Terry at Marlin to see if they have the stronger ones available.
best regards
Peter

[Peterx]

Re: Breaking mudguard stays.

I've now found the re-call notice which reads as follows........

11th January 2008, 17:54
Calling all builders
We have experienced some breakages on our front mud guard stays made using a light tubular material. As a result of this we have decided to offer a free replacement service, (we do need the tubular mud guard stays returned to us in order that we can re-supply stays that our made to the correct fitting pattern).

We think there may still be a few of these old parts being used so this is just pre-cautionary note ............ check.

Best Wishes
Terry & Mark

[mlplatt]

Re: Breaking mudguard stays.

Thanks Andy and Peter for your inputs. The idea of fixing the mudguard directly to the chassis is one that David and I have discussed and will now re-examine. The simplest option though is to take advantage of Marlin's offer as Peter suggests and I have emailed them asking them to confirm that this still stands. Ideally I would like longer mudguards as a fibreglass extension would be lighter than mudflaps but I doubt my skills are up to that.

Thanks again to you both.

Malcolm

[Patrick]

Re: Breaking mudguard stays.

There is a copy of the recall notice on my website:

http://www.msportster.co.uk/faq.asp?FAQ=22

Mine broke after 50miles. I've since replaced my carbon fibre wings and customised the replacement wing stays.

Thanks, Patrick

[Peterx]

Re: Breaking mudguard stays.

Thanks, Patrick, I forgot they where on your website!

A good reminder of the front suspension wishbone re-call on BMW Sportsters as some new MOC members may not have seen that either?
...peter

[Patrick]

Re: Breaking mudguard stays.

ooh oops typo in my message, meant to say I replaced my fibreglass wings with carbon ones. Save about 1.4Kg in unsprung weight too

Patrick

[mlplatt]

Re: Breaking mudguard stays.

Patrick,

Are the details of your carbon fibre mudguards and customised replacement stays available? I looked at your web site (very nice) but a cursory glance didn't reveal them.

Thanks,

Malcolm

[Patrick]

Re: Breaking mudguard stays.

Malcolm,

The construction pictures start at the bottom of this page and go one for the following 4ish pages: http://www.msportster.co.uk/detail.asp?cat=10&offset=168

There's two pictures before the wings went back on after painting here: http://www.msportster.co.uk/detail.asp?cat=28&offset=0

The news story related to the carbon wings is about 2/3 down this page (search for carbon wings once it's loaded)

http://www.msportster.co.uk/build.asp?offset=200

My site needs a great deal of clean up. It started quite small and grew much bigger than I had original design it for. I must sit down at some point and sub divide / categories all the photos much better

Thanks, Patrick

[mlplatt]

Re: Breaking mudguard stays.

Thanks Patrick. Found the details on your website. The guards look very smart but I am afraid they also look rather expensive. Also they look no longer than the standard Marlin ones whicjh I have found rather ineffective without the addition of vast mudflaps in keeping the car free of large dollops of cowshit and other assorted debris.

Incidentally did either Peter or yourself receive an email from Marlin about this problem or was it just published on a website? All I have received was a notice about the suspension.

Regards,

Malcolm.

[Patrick]

Re: Breaking mudguard stays.

The wings are by carbonmods.com don't remember where I bought them, maybe merlin motorsport.

Not cheap but I felt from a safety perspective 600 grams would do a lot less damage than the heavy standard wings if they came off. The weight reduction was just an added bonus

thanks Patrick

[mlplatt]

Re: Breaking mudguard stays.

I looked on the Carbonmods site. Costly indeed but agree with you about the safety factor. On the other hand if I need heavy mud flaps?

Did Marlin email you about this fault?

Thanks,

Malcolm

[Patrick]

Re: Breaking mudguard stays.

There some stuff further down this forum regarding the wishbone failure on my sportster. The recall happened after that date.

I believe carbon mods do a mud flap material as well - their service is very good

Thanks, Patrick

[Peterx]

Re: Breaking mudguard stays.

Malcolm,
I can't remember if Terry emailed the wing stay re-call? I think it was in one of their annual newsletters and it was definately posted on the Madaboutkitcars forum.
regards

Peter