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Old 10-29-2011, 08:34 AM   #31
Advdave OP
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Box ready to ship

I've got another R1200GS/A toolbox done and ready if anyone is interested, let me know.
Box is $120, paypal fee is $4, shipping is $15, so bottom line is $139 shipped in USA.

Mounts are set up for OEM pannier frames.

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Old 10-29-2011, 04:02 PM   #32
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PM sent, I'll take it.
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Old 10-29-2011, 04:29 PM   #33
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Thanks, Tom, in the mail on Monday.

I have one more that'll be done on Monday if there's any more interest.
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Old 11-11-2011, 06:31 AM   #34
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I installed this the other day. It's the cats ass! Holds a lot more than I thought it would. Air pump, tire repair kit, tools, I just keep cramming stuff in there. Love the big wide door that it opens from the side.
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Old 11-11-2011, 07:13 AM   #35
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Know what you mean...here's the stuff I have in the tool box:

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Old 11-11-2011, 02:22 PM   #36
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PM sent
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Old 11-11-2011, 06:33 PM   #37
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Old 11-11-2011, 09:25 PM   #38
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Tool Box GSA

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Old 11-14-2011, 07:10 PM   #39
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thanks Dave. Got it today as promised. Looking forward to the install. Thanks for the instructions.
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Old 11-18-2011, 04:53 PM   #40
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I wondered about that other box's clearance. The tolerances are fairly close. On mine, I've cut the corner off to add room for the brake bleeder. It's worth watching to make sure it clears, but mine is working fine. I rode 2600 miles on the Continental Divide Route last summer and the box is still attached as solid as when it started. For mounting the top, I'm using a 1/2" conduit clamp (painted black on this installation) attached with a 1/4" stainless steel bolt with a flat washer and nyloc nut inside the box. The bolt goes through the box edge that's double thickness and so far, seems to be holding up just fine. Lower mounts have changed a bit, instead of 2 separate tabs on the box, I have started using one full width piece that's incorporated into the box and riveted on the bottom with L brackets and on the face with all the rivets in the lower part of the hinge as well (see post #31 pic).



Here you can see the area given up for the brake bleeder clearance.

Tolerances for clearance to the crud catcher are close too, although usually the crud catcher will shear it's own mounting bolts and fall off with sustained bumpy riding, so I just removed it.

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Advdave screwed with this post 11-18-2011 at 05:01 PM Reason: pfix speliing
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Old 11-21-2011, 09:25 AM   #41
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project status

Have 2 inmates on the wait list. If you're interested in a box, PM with your email address. Need to order more materials and I'll start on a few more boxes.
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Old 11-21-2011, 10:02 AM   #42
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I'll take a couple of dozen

Dave,

Crank out a couple of dozen for me. Maybe we can take a ride next Spring when you finally emerge from your shop!

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Old 11-21-2011, 11:50 AM   #43
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Kenedian boxes

Hi Ken...

I have a special price for you if you need 'em built to metric standards. eh?
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Old 12-09-2011, 07:16 PM   #44
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More boxes ready to go

I have a couple of boxes ready to ship and more in the works. This one I mounted on the bike to check clearances, so it'll come with mounting holes already drilled. Have another undrilled box ready to go.

Some have asked about sealing the boxes. When they are assembled, the joints are sealed. The boxes are pretty water tight, but the door and hinge are not. Some have used gaskets or seals. I use a tool roll and water hasn't been an issue.

Aluminum is .050" stock, makes for a nice solid box. Rivets are stainless steel.

Price still $120 for the box, $4 to paypal if you use that, and $15 flat rate shipping in USA total delivered then, is $139.

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Advdave screwed with this post 12-09-2011 at 07:22 PM Reason: add photo
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Old 12-16-2011, 06:58 PM   #45
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ToolBox 2.0

A few changes and improvements:

A timely buy at the local metals yard yielded a bit heavier aluminum stock.

I've switched from stainless steel pop rivets to solid aluminum aircraft rivets. The rivets are very secure and leakproof.

Finally, I located some "Harsh Environment" hinge material, and by bedding the hinge at install, we've got a pretty leak resistant/tight hinge now.

Some of you have added gasket material around the door. That, together with the solid rivets and sealed hinge makes for a fairly weathertight box.

This box fits the R1200GS/A with OEM panniers.

I'll have 6 boxes ready to go in about a week. Price unchanged...$120 for the box, $4 for paypal, $15 for shipping in USA.

If you PM, give me an email address and I'll get back to you that way.

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