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Offline Dieselram94Topic starter
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« on: August 06, 2013, 02:44:41 pm »
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When I purchased my Xterra used it showed up with broken mounting ears on the stock concentric coil. I use the dd coil that also came with it instead. Anyone know of a good fix for this problem?

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« Reply #1 on: August 06, 2013, 08:49:18 pm »
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You do not state whether it was a New or Used Purchase.

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« Reply #2 on: August 06, 2013, 09:13:34 pm »
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Dieselram, This is a bad problem but not unfixable. You will have to build a cradle to support the coil with an extention above the coil on which new ears can be mounted.  Think of two flat plates with The coil sandwiched between them. and the ears mounted on the top plate. You will need material which is not flexable. I would suggest polycarbonate. The plates can be cut out to reduce weight and fastened with nylon wire ties and nylon bolts and nuts if necessary.  The wings can be simple 90 degree angles with holes drilled for mounting on the upper plate. I suggest you try to find an old Hp printer and cut some angles from the plastic case. These cases are extremely strong. This fix won't be pretty but it should work and be stable.

An alternate fix for broken plastic and or non weldable or glueable metal parts involves stiching them back together with .03 nylon monofiliment. Repairs made in this way can be made as strong as the original material if there is enough left to stitch to.  You will need an inflexable reinforcer for each ear and a dremel tool with a .o35 drill and a bit of patience. I would put epoxy between the broken ear and the reinforcement. not to glue them but to stabalize the joint.  Good luck Gambol

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Offline Dieselram94Topic starter
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« Reply #3 on: August 06, 2013, 10:18:21 pm »
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Quote:Posted by homefire
You do not state whether it was a New or Used Purchase.

I purchased it used and the previous owner packaged it in the original box with the dd coil as well. Not enough room and the stock coil got broken. Even though it was insured the seller dropped the ball on the claim to Fedex. He was retired military so I just let it go...

Posted on: August 06, 2013, 10:16:31 PM
Quote:Posted by gambol1
Dieselram, This is a bad problem but not unfixable. You will have to build a cradle to support the coil with an extention above the coil on which new ears can be mounted.  Think of two flat plates with The coil sandwiched between them. and the ears mounted on the top plate. You will need material which is not flexable. I would suggest polycarbonate. The plates can be cut out to reduce weight and fastened with nylon wire ties and nylon bolts and nuts if necessary.  The wings can be simple 90 degree angles with holes drilled for mounting on the upper plate. I suggest you try to find an old Hp printer and cut some angles from the plastic case. These cases are extremely strong. This fix won't be pretty but it should work and be stable.

An alternate fix for broken plastic and or non weldable or glueable metal parts involves stiching them back together with .03 nylon monofiliment. Repairs made in this way can be made as strong as the original material if there is enough left to stitch to.  You will need an inflexable reinforcer for each ear and a dremel tool with a .o35 drill and a bit of patience. I would put epoxy between the broken ear and the reinforcement. not to glue them but to stabalize the joint.  Good luck Gambol

Thanks for the reply. I just threw away an old HP all in one printer the other day. Oh well, I will find another.

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« Reply #4 on: August 07, 2013, 09:14:15 am »
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Can you show a photo of it?    If you have all the parts they may be able to be cemented back.     I guess I need to learn to read better.   LOL   

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« Reply #5 on: August 07, 2013, 09:29:02 pm »
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I have all the parts. Unfortunately both sides are broken. I will try to post some pictures tomorrow. Thanks!

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« Reply #6 on: August 08, 2013, 09:26:16 am »
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I have had GOOD success using ABS cement.  If the Breaks are Clean, I just use the Cement and may add some additional ABS Plastic on the outside of the Ears after the original parts have been cemented.   

Here are some Ideas for you.   

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http://faq.ninja250.org/wiki/Plastics_repair_with_ABS_cement


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« Reply #7 on: August 08, 2013, 04:12:00 pm »
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I am very interested on this type of a repair. Waiting for the photos.

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Offline Dieselram94Topic starter
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« Reply #8 on: August 08, 2013, 11:46:46 pm »
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Here is a picture of the broken ears...

Posted on: August 08, 2013, 11:33:35 PM
Homefire, that is a pretty cool link you provided. I wonder if I V each side of the break and try the abs cement trick if I could then make a piece for the outside of each ear and cement them into place and then use a longer nylon bolt to remount the coil?

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« Reply #9 on: August 09, 2013, 12:42:56 am »
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Those are Nice Clean Breaks.  I think you will do fine with the Cement alone.   Let it cure for a good day or two.   Grin

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