RGS Inner fairing broken threaded insert for instrument panel securing bracket

[murphus]

So here's an interesting conundrum. Pulled the instrument panel from my '83 RGS and found somebody's been in there before (no surprise), evidenced by loads of electrical tape wrapped around the instrument panel. Obviously some sort of work was being done. FWIW, I've owned the bike 19 years, first time I've removed the instruments. The bigger issue is the threaded insert for the bolt that secures the left side panel retaining bracket. There's one on either side. The insert is broken, obviously stressed biggly the last time the panel was removed/installed. So now what to do? The inserts are clearly pressed in place and not meant to be removed/replaced. The retaining bolt threads in, loosely, and predictably looses grip/strips when any real torque is applied. Looking for suggestions for repair. Or, alternatively, does anyone have a good inner fairing they might sell? Pics show the broken insert and taped up instrument panel.

 

[Andy]

I've repaired a couple of those things on similar projects (not on an RGS) and those inserts were probably moulded in place so can be a bit awkward to replace, but I'd be looking for something like this for example: https://www.theinsertcompany.com/brass_hex_drive_insert_for_wood_headed.php
Have the plastic warm and heat up the insert before screwing it in gently so it doesn't stress the plastic. Hopefully it'd stay reasonably stuck in place but if not then I'd unscrew it and add glue. Alternatively you could just glue an insert in from the start but that can make it tricky to get the angle perfect without a jig. Then obviously use a smear of grease on the bolt.

 

[Cccg]

Remove the existing nutsert, fill the existing hole with a plastic repair kit, fibreglass , devcom or liquid metal.
Re drill the hole in the correct spot and fit a new nutsert, usually a nine mm hole depending on the brand of nutsert.

 

[murphus]

Remove the existing nutsert, fill the existing hole with a plastic repair kit, fibreglass , devcom or liquid metal.
Re drill the hole in the correct spot and fit a new nutsert, usually a nine mm hole depending on the brand of nutsert.

It'll be interesting trying to remove it without damaging the surrounding area, but I think that's probably the surest repair as the nutsert is pressed in, not screwed in.

 

[murphus]

Different approach: Instead of trying to remove the broken insert I loaded the cavity with epoxy and threaded a stud into the damaged insert. It's straight, tight. An easy solution. Well, at least so far. I suppose one could call it a bodge job, but hey, it's invisible.

 

[murphus]

This is maybe minorly interesting: Working on both my RGSs right now, an '83 and an '84. Have the fairings off both. Inner fairings are different moldings. The underside/backside of the '83 is smooth, the '84 is ribbed. Was there an issue with inner fairings cracking/failing, hence the ribs for strengthening?

 

[Andy]

My '84 is also ribbed. I kinda wish I had that smooth version, probably ultra-rare and expensive, especially with the bespoke stud/nut combo

 

[murphus]

My '84 is also ribbed. I kinda wish I had that smooth version, probably ultra-rare and expensive, especially with the bespoke stud/nut combo

I'd be more than happy to sell it to you for an absurd price ... with an additional 20 percent for the "custom instrument panel retention system."