I took the Turbo R up to the mountains for a ride last Sunday and I quickly discovered that the hinges on my new Jemco PXP Xtreme cargo box are just a little loose and pop out too easily. See video:
Jemco PXP Xtreme loose hinge
If the lid was shifted just a little bit right or left on the cargo box, just opening the box all the way would cause the hinge to pop out. It was pretty irritating. I thought of several ways to fix it on the drive home. I eventually came up with the fix below that I am pretty proud of. I took some pics for anyone else that might run into this issue.
I reached out to my contacts at Motoalliance/Jemco to let them know about the issue and also showed them how I fixed it.
I purchased some Tee nuts, counter sunk screws and some shoulder bolts at the local Ace hardware. I wasn't sure how long the shoulders would need to be on the bolts so I purchased two shoulder bolts with a slightly longer shoulders. I ended up using the shorter ones.
The holes for the screws that hold the Tee nut in were not counter sunk so I just used the tip of a 1/4" drill bit and counter sunk the holes a little.
Next I drilled a hole in each side of the lid in the center of the hinge for the Tee nut to be inserted. I drilled the hole for the Tee nut so that it was tight enough that I had to tap the Tee nut in. Don't make this hole too big or it won't be very strong.
Here I inserted the Tee nut and put the two screws in the holes to hold the Tee nut in place. I'm sure those little screws would rip out pretty easily but any force on them from opening the lid will not be pulling on them. If the hole for the Tee nut is tight, I think it will be pretty strong.
Next I drilled a hole in the cargo box side of the hinge that is just big enough for the shoulder of the shoulder bolts to go through. The shoulder bolts will be coming through from the back side of this hole and into the Tee nut in the lid side.
I found a washer in my misc leftover nuts, bolts screws and washer bin. In this pic, I just put the shoulder bolt and washer into the T-nut lid to show how it works. After this pic, I took the bolt back out and installed the lid back onto the cargo box as normal. With the reduced clearance from the Tee nuts on the ends of the hinges, I had to use a flathead screw driver to pry the hinges back in place when installing the lid. This reduced clearance alone from the Tee nuts would probably keep the lid in place but I took it a step further by installing the shoulder bolts.
It's not super fun to reach but you can get up in the cargo box and install the shoulder bolt and washer from inside through the holes and into the T-nuts in the lid. The lid and hinges are 100% secure and better than new I think. Photo from inside of the cargo box showing the shoulder bolt head after it's installed:
Here are the item SKUs at ACE:
2X Shoulder Bolts:
2X Tee nuts:
4X of these little counter sunk screws:
All in about $9 and it shouldn't take more than about 20 minutes to do the whole job.