I would like to introduce my project which I have started at about two years ago. My aim was to produce rack in which can be mounted tool box.
After many experiments and tests, here is the result:
The tool box is with 7 litter capacity.
Besides the convenience to have the tools always at hand, without the need to put external suitcases. There is also another advantage – you have bigger luggage capacity with smaller dimensions of the motor with mounted panniers.
For R1150GS the width of the motor with mounted panniers is as follows:
2 suitcases x 35 litters + 7 litters toolbox – 90 cm.
2 suitcases x 40 litters + 7 litters toolbox – 96 cm.
2 suitcases x 45 litters + 7 litters toolbox – 102 cm.
Regarding the panniers:
They are made of 2 mm aluminium sheets, welded and powder painted. The method we use to attach the bottom of the pannier to the body makes the bottom edge 4 mm thick.
The pannier is mount to the rack in 4 points, which helps more evenly distribution of the luggage load, and hence greater endurance of the panniers.
The lid is attached with two hinges and two toggle latches with a tensile strength of 400 kg.
Suitcases are dust and water impermeable.
The stand for the upper-case is made so that it can easily be used for Luggage rack.
We are currently developing a system for R1200GS.
More information you can find here: www.bumot.eu
If you have any question I am on your disposal.