1983 R100RS Rebuild: Pannier Plastic & Latch Repair

In 1983, the R100RS came with BMW branded panniers, or saddle bags. Mine have a number of cracks and a broken lid hinge. While I’m waiting for some fork parts to come, I started to repair the panniers. My goal was to try and make the crack repairs invisible.  I think I got a B+ this time and learned a lot about how to create the textured surface in the plastic on the outside of the pannier.

I’ve tried a plastic repair product, Plast-aid, before to fix the bulkhead connector on a Windjammer fairing. I’m using it on the panniers. It can be colored using Acrylic paint so the Plast-aid color will match the black panniers.  I also fixed a broken latch assembly and learned about locks and keys and how to figure out what key you need for a lock. Here is the link to the write-up on what I did.

I discovered that two different keys are not enough for all the pannier locks. Some have been replaced so I have four different locks needing four different keys. I posted a note to the Micapeak  Airheads forum about this and learned that the latch locks are no longer available, but, Larry Stonestreet, owner of Stoner’s Beemer Stash [[email protected]; 951-813-1704]  has the keys I need. So all’s good. There is a nice page on Bob Fleischer’s site about the locks and keys BMW has used with part numbers of the various keys.

Here are some pictures from the write-up.

Double Latch Cracks

Double Latch Cracks

Mulitple Corner Cracks

Crushed Corner With Multiple Cracks

Double Latch Crack Final Repair

Double Latch Crack Final Repair

Crushed Corner Final Repair

Crushed Corner Final Repair

Plast-Aid and Black Acrylic Paint for Tinting

Plast-Aid and Black Acrylic Paint for Tinting

Round Dremel Bit for Widening Back of Crack

Round Dremel Bit for Widening Back of Crack

Dremel Engraving Tool #106-A Bit Too Big

Dremel Engraving Tool #106 to Etch Texture Into Plastic-A Bit Too Big, #105 Is Better

JB Weld Applied to Lock Mechanism Hinge Plate

JB Weld Applied to Lock Mechanism Hinge Plate

Pannier #1 Latch Locks Use Key #069

Pannier #1 Latch Locks Use Key #069

Panniers Mounted

Panniers Mounted

Panniers Mounted

Panniers Mounted

Panniers Mounted

Panniers Mounted

2 thoughts on “1983 R100RS Rebuild: Pannier Plastic & Latch Repair

  1. WOW VERY Impressive Brook! As I would expect from your perfectionist previous work, This looks as good as new . Can’t wait to chat about how to fix the blown out bottoms in mine, You truly do provide an invaluable service to all of us in the airhead community! TY

    • Hi Dale,

      Thank you my friend. I want to see your bags when you have a chance and I’m quite sure that hole in the bottom can be fixed using some ABS plastic sheet and Plast-aid.

      Best.
      Brook.

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