CUSTOM SADDLEBAG DESIGN

380 Dwight Street
P.O. Box 1067
Holyoke, MA 01040
osprey@ospreylimited.com
toll free: 877-634-0052
local: (413) 535-0102

HOW TO REPAIR OR RESHAPE YOUR SADDLEBAGS

RESHAPING YOUR SADDLEBAGS :
There is no need to pay anyone to repair or reshape your saddlebags.It is relatively simple.There is no need to buy a kit.
Listed here are the suppliers and directions needed to repair or reshape your saddlebags.The listed suppliers are the same
ones used by saddlebag manufacturers. There is no better way to repair or reshape your bags than the method described here.
Sometimes the leather used by the bags manufacturer will lend itself better to reshaping than other leather. If you are unhappy
with the initial reshaping results, try a second time. If you are still unhappy buy a new set of bags. .Note: Heritage bags made in
the 1990's are difficult to reshape.The leather Harley used does not easily lend itself to be reshaped. However our repair
method will work as well as any.
RESHAPING YOUR SADDLEBAG
1.Soak the bags in hot water for 30 seconds in a laundry sink or bath tub.
2.Stuff the bags with newspaper.It will take at least one Sunday edition.
3. When wet mold the top back into shape.
4.Leave to dry for at least one day.
5. Take out the newspaper.
6. Optional Step. Grind off the buckles from inside the bag and pull the buckles away from the bag.This will allow the
stiffener to lie flatter against the leather .If you feel confident about pop riveting or bolting the buckles back on then go
ahead and grind off the buckles. Otherwise it is not absolutely necessary to remove the buckles.
7.Cut out the shape(pattern) of the flat saddlebag top piece and the saddlebag front from the plastic sheet(see supplier
Modern Plastics) making the pattern 1" smaller on the outer edge so the plastic piece fits onto the top and front.You also
can substitute luan, or 16ga-24 ga metal in place of the plastic.The purpose of the plastic is to keep the bags shape once the
bag is dry.
8.Apply one coat of contact cement to the inside front of the leather bag and one coat to the stiffner.Let dry. Apply another coat.
Push the pieces together almost immediately after applying the cement.Do not let the cement dry before pushing the pieces together.
Work fast.
9 Drill 5/32" holes through the leather and stiffener to provide holes for pop rivets or small bolts(8-32 used with acorn nuts)
Use washers under the bolt or pop rivet head and washers on the other side as well to increase the holding strength.Use
three across the top of the front and a couple lower down.Paint the rivets or bolts if desired to help disguise them.Also install
two on the right side and two on the left side of the top.
10.To reinforce the sides cut plastic strips about 4-5" wide x12" long and cement from the top of the sides. Secure
with pop rivets or small acorn nuts and bolts

HOW TO REPAIR CRACKED PLASTIC BACKS
1. Contact cement small strips of metal or plastic over the crack and pop rivet in place.

SOURCES
1. modernplastics.com 1-(800)243-9696 go to sign plastic materials&products then sheet products for signs then choose sign HDPE sheet .055"x24"x48"
2.pop rivets and 8-32 nuts and bolts and washers -your local hardware store-Home Depot
3. Leather for strap replacement Osprey Limited PO Box 1067 Holyoke Mass. 01040 Measure the strap with both length
and width and write a letter describing needs . Send a check.We will send enough leather for $12. for 4 straps.Cut the straps
with a sharp utility knife.Do not call the order for strap leather.Order only through the mail. Website http://www.saddlebags.net