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RAM 1500 Lumbar Support broken

 
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der.harleyman
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Joined: 12 Jun 2013
Posts: 6

PostPosted: Wed Jun 12, 2013 4:30 pm    Post subject: RAM 1500 Lumbar Support broken Reply with quote

Here you can find a way to repair your broken lumbar support that lasts.
I send you this little description from Germany. So please keep in mind I´m writing in a foreign language. If you find any misspelling, you´re allowed to keep it.

How to repair a broken lumbar support when there is actually no fitting spare part around, you want to save money and want to have it fixed forever? This is my way:

First of all lift your seat cover half way up so you can remove the parts shown in the following pic.



[img=http://abload.de/thumb/sam_0583dfrra.jpg]

Here you can see the broken lumbar support screw [1], the lumbar support console taken from inside the seat [2], a sleek nut (used to build furniture) [4] and an old piece from a bicycle brake [3]. We´ll need the eye bolt that holds the brake shoe later.



[img=http://abload.de/thumb/sam_0585vqqg1.jpg]

Drill through the white plastic screw with a 6mm drill



[img=http://abload.de/thumb/sam_0586pnofq.jpg]

Flat grind the plastic bolt, so there is nothing left from the broken eye.



[img=http://abload.de/thumb/sam_0587y6p8b.jpg]

Time to take a look at the nut. It is 7,5mm outside
I drilled the plastic bolt with a 7,5mm drill at the opposite end of the eye. Just drill deep enough to get the nut inside. No need to drill completely through, as we want to keep the plastic bolt as strong as possible.
You might take any eye bolt or nut you can find around. Be shure to keep the nut as flat as possible to keep the whole way to adjust your lumbar support. With a thicker nut you´ll have less adjustment on your lumbar support!



[img=http://abload.de/thumb/sam_059307pdw.jpg]

Here you can see the nut [4], the drilled plastic bolt [1] and the eye bolt from the old bicycle brake. (From left to right)



[img=http://abload.de/thumb/sam_0600n7osc.jpg]



[img=http://abload.de/thumb/sam_0601wcq1b.jpg]



[img=http://abload.de/thumb/sam_0603ysp2j.jpg]

Apply a drop of locking compound LOCTITE o.e. to the bolt and screw these three parts together. Looks much better than the old plastic crap doesn`t it?



[img=http://abload.de/thumb/sam_0599l5pb4.jpg]

Time to complete the pieces. Take a closer look. The bolt is already in place.



[img=http://abload.de/thumb/sam_0611j0pvx.jpg]



[img=http://abload.de/thumb/sam_0613olqhs.jpg]

After completing your improved lumbar support it´s time to go back to the car. Get all pieces in the original place and find out how it works. Shure it will, because you know how to build a lumbar support that lasts...!



Wink

Disclaymer: if you take the brake parts from someone elses bike, be shure to inform the owner of the bike before he uses the bike next time. If it´s the bike from your wife, you might have lots of trouble later (when she comes back...).

Best regards from Berlin, Germany
harleyman

(who is working on his wifes bee #1687) Razz
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Da Beest
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PostPosted: Thu Jun 13, 2013 5:24 am    Post subject: Reply with quote

Nice work my friend. Appreciate your effort.
I made this a STICKY so it would be easier for members to find.
Thanks!

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abitwar10
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PostPosted: Thu Jun 13, 2013 12:29 pm    Post subject: Reply with quote

Jesus-H! Reduce the size of your photos next time... we're not all blind like Joe.
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Ken

2003 Harley Davidson Vrod (Black)
Second Swarm 4x4 #4266 (Yellow)

K&N drop-in, Truxedo low profile tonneau, AT3030, Bed Rug, Honeycomb Ram floor mats, stripe extensions, custom pedals, Honeycomb Grille, SRT wing, MRK accents, custom etched Chrome fuel door, '06 Chrome Ram Wheels, Infinity reference components powered by Pioneer, JL 10w6v2 in a HotBox powered by JL Audio
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Bill_L
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PostPosted: Thu Jun 13, 2013 6:06 pm    Post subject: Reply with quote

I'm interested in viewing this but with pictures that are 4320x3240 I am not even going to try which is really bad since my monitor is a 32" 1080p tv.
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Da Beest
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PostPosted: Thu Jun 13, 2013 6:56 pm    Post subject: Reply with quote

abitwar10 wrote:
Jesus-H! Reduce the size of your photos next time... we're not all blind like Joe.

I can see just fine. dunceblock

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der.harleyman
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Joined: 12 Jun 2013
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PostPosted: Fri Jun 14, 2013 3:48 am    Post subject: Reply with quote

Yeah, I was shocked too, but to late. Next time smaller pics, ok! It was getting late that day and my own eyes were tired... not? I am to old for this modern stuff I suppose...! confuzzled
You can mouse click on each pic to get a smaller version. gt-happyup

harley
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