Carrying extra fuel

[Tread]

I recently purchased a R1200GS and, while the fuel range is certainly adequate, I wanted to have a good way to carry some extra fuel. I looked at a lot of other techniques, but most of them had fuel bottles either mounted to the aluminum side case or to the frame that holds the side case. I bought my GS with the Vario cases and neither of the aforementioned techniques will work. The cases are plastic and they don’t have a full frame like the Adventure style cases.
I think I have come up with a fairly novel way of mounting a fuel bottle to the frame. My method is very solid. It does not involve making any permanent modifications and the parts are easy to acquire. First, the parts list:
1” Tube (.75” Pipe) Cushioned Pipe Clamp, Qty 2 (Grainger part # 1RVC2)
3” Tube (2.5” Pipe) Cushioned Pipe Clamp, Qty 2 (Grainger part # 1RVC9)
3/8" x ¾” bolt, Qty 2
3/8” lock washer, Qty 2
Thread locking compound
MSR 30oz Fuel Bottle
Here are the parts prior to assembly. I have cut the heads off the bolts, we won’t be needing those. I also used a roll of some clear protective adhesive vinyl protect the finish of the bottle. Purely optional.

Next,
I removed the rubber lining of the larger clamps. The clamps are otherwise a bit too small. I also threaded the bolts into the 3/8” nut that comes welded on to the clamp. I used a little thread locking compound here.


Using the lock washer, I attached a small clamp to the large clamp. Again, a little thread locking compound. Align the clamps so they face the same direction.


Here are the two finished brackets.


Here it is with the bottle installed.


Mounting on the bike is simple. Use the 1” dia frame member as shown.


There is plenty of clearance for the rider. You could even mount a bottle on each side.


I haven’t tested it yet but I don’t think it would pose a problem for the pillion either.


Plenty of clearance for the side case.


The mount is very sturdy. There is a slight amount of flex due to the rubber cushion on the frame clamp. This is probably a good thing. It will protect the paint as well as act as a vibration dampener. The total cost for the bracket was about $26 and another $20 for the bottle. Total assembly time is about 15 minutes.
As soon as everything thaws out around here I will have a chance to road test it, but I can’t imagine any problems.

[caljw]

Very nice....and a first post! Where did you get the clamps? Thanks may give it a try. BTW white font is better for us old guys

[Tread]

Font color fixed. The clamps are from www.grainger.com and the part numbers are listed in the original post.

First post, but I've been lurking for a long time. New to the "Adventure" bike world. Previous bike have all been purly street oriented, RT, FJR, etc. That didn't mean I always stayed on the paved roads, hence my most recent purchase.

[peanut_gallery]

I like that a lot better then the one gallon tank i bungee net to the back whne i need it. But I dont think it would work with the Jesse brackets since they have a forward support in roughly the same area.

[Stinkyb]

Thems Be Caddyclips. use them quite alot at work. Only issue I would see is corrosion on the steel....granted, you didnt really pay much anyways
I would still try to use the rubber rings. In most cases you can make them work, you'll just have to extend the retainer bolt further out. Worth a try.

[bananaman]

Very nice. I bet you could do a bigger bottle, too. Cuz one quart isn't going to get you very far!

[funhouse]

I don't know why, but my 'that's gonn'a break after a 100 miles of washboard' radar lite up when I saw the pictures. Nice workmanship, good placement, quality parts. Let us know.......Bruce

[Tread]

The rubber cushion on the larger clamp had to be removed or there would be no way to make it work. The cushion is pretty thick. I suppose you could use a cross section of a bike inner tube.

Regarding corrosion, perhaps if left on all the time in parts of the country that are suseptable, then corrosion might be a problem. I don't plan on leaving this on all the time. It only takes a couple minutes to completely remove it.

Time will tell, but I don't think there is any chance of it breaking. The smaller clamp is rated for 180 lbs, the larger for 300 lbs. The bolt that holds them together is pretty stout at 3/8". I think there is a lot of other stuff on the bike that would break before this. The only thing I could see happening is for the clamp to rotate downward causing the bottle to pivot outward. The small clamp is all the way tightened onto the frame and it takes a fair amount of force to rotate, but with enough vibration I guess it could happen. It would be easy fix if that does turn out to be a problem.

[Tread]

Originally Posted by bananaman

Very nice. I bet you could do a bigger bottle, too. Cuz one quart isn't going to get you very far!

If it gets me 10 miles then it was well worth it.

[imonec]

Nice post!

How much do you fill up the extra bottle? I can see pressure buildup, additional shaking, heat and "doh, I just sprayed gas in my face" when you open up the cap to be a problem...?
In this case fuller will be better, but difficult to do when mounted i would imagine, have to remove the bottle to fill it up, or do you use a funnel?
How's it holding up on vibration and the odd kick from the passenger?

Nice job!

[engjacques]

I carry a bottle bolted to my vario cases - just need bolts long enough to get through the double skin, I have it so it doas not impede the expandibility of vario cases

[Makalu]

Nice idea. I haven't seen those clamps with the nuts before.

How about adding a wing nut screw so you can get the bottle out with out tools?

[jgas]

Downey fabric softener bottles work great. They are strong, flexible, and the lid seals very tightly. They even have an internal rubber gasket built into the cap. They seal better than anything I've tried, although I still put a little wrap of duct tape around the cap to make sure it doesn't get unscrewed. If I don't put it inside some piece of gear that is mounted to the bike, I use the heavy duty extra wide zip ties.

Old plastic or metal army canteens work great too. They used to sell for a buck a piece at army surplus stores, but now they try to get 5 or more dollars apeice. They are getting a bit more rare since the days of the Camelbak.

MSR usually has pretty good products. I bought some stuff from them thinking it was Malcolm Smith Racing. Nope. The MSR camping products company used to lobby very hard against any type of off road vehicle use. I haven't kept up with the companys stand lately, but a few years ago there were posts on many motorcycle websites pointing out their stand, asking riders to boycott them. I remember reading several statements from MSR saying all off road use of any motorized vehicle should be banned by the government. MSR also gives HUGE donations to the Sierra Club, Greenpeace, and other orgs who are trying to kick us out of the woods on bikes. A company called Burts Bees was working with MSR and many other businesses to end all access to any off road trails, roads, or areas. I will never buy another MSR product, and will spread the word of their fascist behavior. A funny thing is that the other MSR, Malcolm Smith Racing, is a staunch supporter of our off road rights.

[Hikertrash]

Great first post. Much better than whining about water marks or boot scuffs on your panniers
I've seen some folks with the MSR bottles mounted there, but never saw how they mounted them.

You could also throw one of these in your panniers

http://www.redagascan.com/

MSR also supports killing terrorists, so I bought their coyote brown canisters for my spare fuel.

[billdonna]

Nobody else has said it so I guess I will. As a former firefighter, I always think the worst. What happens when you are sliding down the road on your side? Would it not be a little safer to carry the bottle in your Varios where it is protected and bolt something non-flammable on the outside?