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Old 02-18-2013, 11:01 AM   #1
Maoule OP
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Joined: Nov 2012
Location: KCMO
Oddometer: 370
Eek Toolboxes

I actually finished these last week but haven't had time to post. Frickin' work..
Anyways...the particulars:
'11 Adv. 990R;
Happytrails SU luggage racks;
Pelican 1550 panniers;
stock exhaust.
I didn't take enough intermediate pics of the process, so I'll try to explain in detail.

Two 16" pieces of 4" aluminum square tubing, 1/8" wall thickness. I welded a cap on one end. I fabricated a cover from 20 ga. stainless. The hinge is 6mm stainless rod through 3/8" alum. tube (1/4" rod was too tight) with the 6mm shaft welded to 2 ears on the cover:

To fasten the tool box to the luggage rack, I welded a pc. of aluminum angle 3/4"x1/8"x? (I don't remember the dimension, only that it fit between the alum. pannier pucks). The space provided by the 3/4" angle was a snug fit for the 3/4" Happytrails rack:

The 3/8" aluminum tube on the cover was welded to the bottom of the toolbox after making sure of correct spacing for a rubber seal.


The stainless locking latches were installed by welding the small side to the cover and bolting the other side to the box with 2 flathead 10-32 screws and locknuts. The entire unit was fastened to the luggage rack with four 10-32 machine screws countersunk into the 3/4" angle and threaded (and locktited) into the luggage rack. There's not a lot of meat in the tubing thickness of the rack, but I'm hoping with the snug fit, the screws won't vibrate out.


I'm using a small master lock for security. I gave her flowers for Valentines Day...she should, at least, wash the bike for me

Here's a shot with the panniers removed:


I painted the toolboxes with some Rustoleum hammered finish paint. I have a 21" tiretube and a small hand pump stored so far; my goal is to move the weight stored under the seat and glovebox to the rack-mounted toolboxes.
Additional thoughts: I considered mounting the toolboxes to the panniers, but the additional hassle of removing the pannier and leaking potential in the pannier changed my mind. Also, some quick calculations show that these dimensions would hold almost 1 gallon of liquid Anybody have some thoughts on the feasibility of plumbing to the existing fuel system or adapting a quick removal setup? Also would this be safe/durable enough for fuel?

Maoule screwed with this post 02-18-2013 at 11:14 AM Reason: pics
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Old 02-18-2013, 11:03 AM   #2
Mr_Gone
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Brilliant!!! Great job.
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Old 02-18-2013, 05:16 PM   #3
bob393
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Nice work!
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Old 02-19-2013, 04:51 PM   #4
Scott Baja
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Very clever, you should be proud!
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Old 02-20-2013, 05:02 AM   #5
bikerfish
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where do we put our order in?!!
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Old 02-20-2013, 03:42 PM   #6
Maoule OP
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Too much customization for the mounting. Plus the making the lid and welding it to the box was a PITA. I do plan to dig deeper into making auxillary fuel tanks using the tubing;)
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