Tool box setup for 950/990 - AWESOME!

[bikyto]

Actually, I only removed the bottom brackets held by the 4 bolts that meet the transport plate. And it slides right in. I didn't touch the attachment points.

See the pix below:

[ktm950se]

Those brackets you removed are what the Red Hook Strap - 8' is supposed to be connected to when you're winching, and as directed in the winch manual (stated below) correct?

The RED strap must be used to attach the winch to the vehicle. Attach one end of the RED strapto one side of the mounting plate. Route the strap around the vehicle frame and back to the other side of the mounting plate.

ktm950se

[bikyto]

Ok I understand the confusion.
I do not use the red strap with the two bulky carabiners provided (three total). I've changed those to smaller, lighter (and probably stronger) climbing ones. They fit through the holes left by removing the two plates (as seen in the picture above).

Basically, the same effect as the position/attachment points are moved closer to the winch by the height of the said plates. Instead of using the holes in the plates, you use the holes directly onto the winch frame.

I was using the two plates (pictured above) for the transport plate. Now I will use the tool box for transport but you can still attach the winch to the transport plate as it was initially meant to (with a small mod but I won't get into it since it's about fitting the winch in the tool box).

Sorry for the confusion. I don't have access to my laptop... All done from a "smart" phone. Not easy to work with.

P.s. I'm gonna stop answering from this stupid phone and its "auto-correct". Tired of having to edit the post.

[cjracer]

Originally Posted by bikyto

Ok I understand the confusion.
I do not use the red strap with the two bulky carabiners provided (three total). I've changed those to smaller, lighter (and probably stronger) climbing ones. They fit through the holes left by removing the two plates (as seen in the picture above).

Basically, the same effect as the position/attachment points are moved closer to the winch by the height of the said plates. Instead of using the holes in the plates, you use the holes directly onto the winch frame.

I was using the two plates (pictured above) for the transport plate. Now I will use the tool box for transport but you can still attach the winch to the transport plate as it was initially meant to (with a small mod but I won't get into it since it's about fitting the winch in the tool box).

Sorry for the confusion. I don't have access to my laptop... All done from a "smart" phone. Not easy to work with.

P.s. I'm gonna stop answering from this stupid phone and its "auto-correct". Tired of having to edit the post.

Thanks for the update Chris, I kind of thought that was what you were doing, just didn't test it in person yet.

I'm going to pull these of my winch here and test my rigging gear in that hole setup. I've got some nice rigging kits that we use in the field that I hope to offer up soon. Should save a few lbs over the heavy steel stuff.

[bikyto]

Originally Posted by cjracer

Thanks for the update Chris, I kind of thought that was what you were doing, just didn't test it in person yet.

I'm going to pull these of my winch here and test my rigging gear in that hole setup. I've got some nice rigging kits that we use in the field that I hope to offer up soon. Should save a few lbs over the heavy steel stuff.

I look forward to trying your kit (I find the red strap a bit short as well)

[ktm950se]

With the 2 plates removed, would the holes used to attach the strap's carabiners, or any carabiner for that matter, have the same structural integrity as when the plates are attached.
It sounds/looks like when the plates are attached each carabiner is pulling on 2 bolts/holes of the winch's frame, but with the plates removed you would only be feeding each carabiner through a single hole in the winch's frame.

Is this correct? If so, can each hole handle the load?

ktm950se

[RoundOz]

Originally Posted by ktm950se

With the 2 plates removed, would the holes used to attach the strap's carabiners, or any carabiner for that matter, have the same structural integrity as when the plates are attached.
It sounds/looks like when the plates are attached each carabiner is pulling on 2 bolts/holes of the winch's frame, but with the plates removed you would only be feeding each carabiner through a single hole in the winch's frame.

Is this correct? If so, can each hole handle the load?

ktm950se

That was my first thought. It looks like you could cut the ears off those brackets and bolt them back on with one bolt, while leaving the other bolt hole open to shackle to, or make up a new bracket out of plate, effectively strengthening the one bolt hole it would be pulling on. Not quite as good as the plate bolted with two bolts, but I bet you could dead lift a fully laden GSA with rider and pillion without coming close to the shear strength of the total of two Grade 8 bolts (instead of 4) you would be pulling on. "what about shock loading?" I hear you ask. I say that is the makings of a good story for the grand kids about how you lost your left pinky. There's a lot to lose by making things too safe.

[SierraJeep]

This may have been a very expensive thread for me here. Damn you all...

I really like this tool box idea as it'd fit all of the stuff I currently carry in my tank bag (front and rear tubes, tire irons, a few tools I use regularly, a spiderweb bungee, shop rags, etc.) and it'd fit my compressor that I stuff under my seat (still in it's stock plastic housing because of its built-in tire gauge). This summer I'm planning a two-week trip and I'd like to organize my on-board kit a little better and use the tank bag for other essentials.

So now in addition to the tool box, I have to hunt down a good 2-into-1 system (thinking BDCW ss), a new exhaust (thinking Remus Roxx Ti). The screeming sound you're hearing from my ass is the sound of my credit card in my wallet... Damn you all, again!

[bikyto]

Originally Posted by SierraJeep

This may have been a very expensive thread for me here. Damn you all...

you're welcome!

[FINNDIAN]

I can attest to the toughness of this box. this past weekend I completed one of the toughest one day enduro events there are. rallyconnex.com puts on the Dacre challenge in Ontario Canada. approx 800km with a large portion being very tough to impossible terrain. Cjdesigns box stood up to the test of 17 hours of crashes get offs and abuse and completed the event attached to the first 950 adventure to complete this small bike course with only minor dents and scratches. thanks Craig.

[RoundOz]

(or anyone else...) did you ever check the fit with Jesse racks?

[cjracer]

Originally Posted by RoundOz

(or anyone else...) did you ever check the fit with Jesse racks?

Not yet,

One local rider has the Jessies, but I can't rip his pipes off just to test it. Until he gets a 2-1, I'm out of luck. By looking at it, it should fit, but the back cross support bar might be a bit too high and not give a straight shot into the box like the OEM racks. Nothing I can change on the BOX to fix that.

If anyone in the US would like to try, please let me know. I'll work something out with you.

[Narsisco Lopez]

If someone in the Denver/Boulder area has a set of Jesse Cases, we can toss them on my bike as a test once I get my ESB from CJ's powder coater. Anyone?

[Nailhead]

That's a neat idea doubtless well executed, but that space is where my essential additional fuel goes.

[RoundOz]

Craig, the rear cross brace is not a big deal...my worry was that the way the lower section of the rack that tucks in close to the wheel would interfere.

Nail...it was my intent to use that space for fuel, but the adventure tank won't fit and anything I custom build will be less than 2 gallons. Too much work for too little benefit. I am looking into a ~6g tank for the inside of my Pelican case. Quick disconnect for when I need the luggage space. Not carrying a pillion so I think the weight will be manageable.