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Old 01-09-2013, 10:08 PM   #1
Gonzoso OP
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Joined: Sep 2012
Location: Pocono Mt.s PA
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How to Mount Top Box

I'm putting a Seahorse 540 case onto a 2012 KLR 650 stock rear cargo rack. The plan it to plan out 4 holes and drill so I can still access the tool kit.

I will put silicone sealant around the hole as I tighten it up so I can better water proof it. I'm putting panniers on and probably won't haul much weight in this, 10-15 pounds at most I figure, but mostly clothes or rain gear or my lunch pail for work.

Here is a diagram of my idea for mounting it.

I was thinking that using a rubber bushing between would help isolate the box from the bikes vibration and shocks offroad, although it will be on road 80-90% of the time I do like to play in the dirt.

Does anyone have any suggestions or input on how to mount the box? What kind of hardware I should use? I'd like to do it well, but not make it overly complicated. I'm planning on putting it on semi-permanently, maybe use wing nuts instead of hex heads on the end of the fastener inside the box.

I'm also planning on putting some footman loops on top of the box.
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Old 01-10-2013, 05:11 AM   #2
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Joined: Dec 2005
Location: Maine
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I have an '01 so I don't know the shape of the underside of your rack plastic.

I wonder, though, if you couldn't flip that bolt and use a flanged button-head hex (Allen) bolt to keep the inside bottom of your case a little kinder to the contents. I used Tee nuts inside my cases and it's darn flat, but a bit fiddly to install. With big stainless fender washers too.

I also mounted my top-box directly to my rack plastic. When there was a bit of play it was amplified by the box so it moved far more than the rack's vibration.

Stainless for everything.
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Old 01-10-2013, 01:17 PM   #3
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I doubt the rubber bushings are necessary - I have an old Givi E45 that's bolted to my SW Motech rack - no problems, and that plastic is much thinner than a Seahorse case.

As to the wingnuts I tried that out too then quickly realized I never wanted to take it off.
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Old 01-10-2013, 03:23 PM   #4
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When I bolted my Pelican 1500 to the OEM rack on my DR I used large stainless fender washers and rubber fender washers underneath. I slathered the bolt threads (head is inside case) with silicone sealant first and then used locknuts on the other end. Six bolts altogether. Works fine so far. No water inside.

I agree with p0diabl0 - you probably don't need the rubber bushings. Just use large enough fender washers (eg 20mm or larger) to spread the load on the plastic wall.
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