We developed our hidden, semi-internal hinge as a way to provide a cleaner looking and better performing hinge than the factory hinge and latch setup.  Our new hinges have been very well received and it is a design we are very proud of.

Unfortunately, this hinge is not something that we are able to offer as an "over-the-counter" bolt-in part.  The hinges used in this setup are HD Police hinges that are modified and then mounted into the saddlebag.  Because the tolerances vary between factory fiberglass, factory ABS, and our own one-piece saddlebags, we are not comfortable selling these hinges as there is no way for us to guarantee the hinges we modify for your bags will fit when you install them in your own garage.

We will, however, continue to install them for in-shop customers, whether they be in a factory setup or our own saddlebags.

We have received a lot of interest in regards to the hinges.  Because we will not be selling a do-it-yourself kit, the following instructions illustrate the steps taken in modifying your own hinges.

For the hinge assemblies, you will need Harley-Davidson part number 53427-80 (quantity of 4) and part number 90902-93 (quantity of four).  We also use part numbers 91406-04 (quantity of 2) and 91411-04 (quantity of 2) to build the latch assemblies.

 

	1.  Factory saddlebag.
	2.  Before beginning the install, make sure the inside of the bag is scuffed for adhesion.
	3.  First, you will want to make a set of mounting plates that will anchor into the saddlebag.  Drill a hole into each corner of the plates.
	4.  After making your plates, use JB Weld or another strong adhesive to secure the plates into the bag.
	5.  Allowing the adhesive product to squeeze through the holes will indicate whether or not enough adhesive has been used.
	6.  Remove the extra adhesive to clean up the presentation of the plates.
	7.  A bead of silicone can be used to create a finished edge around the plates.
	8.  Construct mounting plates for the lid mounts.
	9.  Glue in plates.
	10.  Clean up the corners of the plates.
	11.  This is how a factory Police hinge will sit on the plate.  This will not work because the factory hinge will not allow the hinge to pivot properly.  The hinge must be modified.
	12.  Use a bench vise or sheet metal brake to flatten and reshape the hinge. From left to right, a stock hinge, a flattened hinge, a re-folded hinge, and the way the hinge should look once finished.
	13.  This comparison shows how a factory hinge (on left) sits in reference to the modified hinge.
	14.  Next, weld the modified hinge to the mounting plate.  The hinges should sit roughly 14" apart.  You should install your weather-strip at this time as it is crucial to taking proper measurements when installing the lower hinges.
	15.  From left to right a factory hinge, a hinge with one bend, and a hinge with two bends.
	16.  Once modified, the lower hinge will bend over the edge of the saddlebag and hang outside the bag.  After careful measuring to ensure the lid fits the bag properly and that the hinges are in line, weld the lower hinges to the mounting plates.
	17.  Finally, the hinges should be operational.  A small nail can be used to check the pivoting motion of the hinges. Once the hinges are installed and the bike is ready to be reassembled, a factory river or roll pin can be used in place of the nail used for testing purposes.

   
   

Bad Dad Custom Motorcycle Finishes

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