Ammo boxes and homemade rack for panniers- 99 r1100gs

Discussion in 'GS Boxers' started by PigPen67, Oct 1, 2012.

  1. PigPen67

    PigPen67 Ron Grace Jr.

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    Hi,..- I saw a lot of posts on ammo box panniers,... I thought it was a great idea so I went to welding and bending and built a rack and hung a couple of $25 ammo boxes on them!...They are really sturdy! I will post some other pics,... I just have to try and find the other thread where I started out !.... I need a thread GPS !https://plus.google.com/photos/116753680819915263212/albums/5794549830049162305
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  2. johnjen

    johnjen I've Been Resigned

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  3. BMW Blair

    BMW Blair Adventurer

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  4. PigPen67

    PigPen67 Ron Grace Jr.

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    Those look great!.... i love it. They took some old surplus, put some sweat and skill into their product...and priced them fairly. Thats a win/ win!

    Thanks for posting the link.:clap
    #4
  5. PigPen67

    PigPen67 Ron Grace Jr.

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    Hi,..
    Since I know I'm always going to fall over,...the question I ask myself is: ...what do I want to to have happen WHEN I fall over?... Rather than have a bunch of ridgid supports, perpendicular to each other,...I tried to create a pathway for the rack to bend,..stronger and more protective near my kids and wife when we are 2 up,..and flexible and easily repairable towards the rear. I posted a link to the pics of it,...If anyone has any input that would help me protect my passengers more,..I am always grateful.:ear

    https://plus.google.com/photos/116753680819915263212/albums/5794554932994439937
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  6. OPEN RANGE

    OPEN RANGE Runnin out of Time

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    What's the chance you'd have interest in making another set + racks?
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  7. PigPen67

    PigPen67 Ron Grace Jr.

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    Sure!.....what bike?
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  8. Yellow Iron

    Yellow Iron Long timer

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  9. OPEN RANGE

    OPEN RANGE Runnin out of Time

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    Me ol bike is a 97 R1100 GS. Was thinkin it might me a simple duplicate project for yur superb skills :D
    #9
  10. PigPen67

    PigPen67 Ron Grace Jr.

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    Hi,
    mine are modified to be a little bit wider than usual,.. maybe just send me a picture of your exhaust... weather is high or low and then we can go from there....
    #10
  11. PigPen67

    PigPen67 Ron Grace Jr.

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    [​IMG][​IMG][​IMG]A couple of stainless steel spacers, 8 ss bolts, some aluminum and BAM ! .... got a really sturdy GPS mount !.... Touratech = $ 140...... Rontech = $ 25 !... with the leftover money I can get to work on my burrito holder !:clap
    #11
  12. bananaman

    bananaman transcontimental

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    I was thinking the same thing- maybe he could re-do my old '96. It don't need the side cases, but it sure could use some TLC.
    #12
  13. PigPen67

    PigPen67 Ron Grace Jr.

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    I talked to a guy who had the same bike ( 99 r1100GS)... he had 420,000 miles on his !.. I have 160,000. I said "wow !,..what do you have to do to get that many miles on it? "... he said " You have to ride it a lot"....uh,..ya. ...Anyway,.. I'm figuring out some labor pricing for OPEN RANGE for some panniersright now,..I would love to do some repair work on your '97. I'm a carpenter/welder and my work slows down in the winter so I just hide out in the barn,...turn on the radio,..and work more on my own projects !.. Just let me know what you want to do and we can talk about it .:lol3[​IMG]
    #13
  14. DDT Rider

    DDT Rider Been here awhile

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    Has anyone found a way to rig these up to the 1200GSA mounts?
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  15. PigPen67

    PigPen67 Ron Grace Jr.

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    If you use a cam actuated lock..... like the ones they use commonly on a weight bar for exercising. That would be a pretty easy Modification. The ID should be less than 3/4".... with a little creativity you could get it to clamp down once you fold it out the bars on your 1200. I will try to find 1 and se:wink:nd a picture.
    #15
  16. PigPen67

    PigPen67 Ron Grace Jr.

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    [​IMG]Mine simply hang with 90deg brackets.... then small clamps with a wing nut inside just to keep them from shifting. .... the same thing could easily be done with the fold out 1200 racks. Just weld a 90 to hang on the top and a small "C" to the bottom of the box to hold it from shifting forward or back.......Ganbatte!:clap
    #16
  17. PigPen67

    PigPen67 Ron Grace Jr.

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    OK,... I got it figured out finally,.. I had to retrace my steps so here's what I came up with:
    Materials:
    RACKS
    10' steel tube (thick wall)
    3ft 3/16' angle steel
    2 cans hammer black paint
    4-8mm bolts
    2-5/16' bolts
    stainless steel wing nuts, and washers and lock washers
    Materials: $ 53.80
    Labor: $ 148.00 ( 4hrs @ 37/hr)
    Total (racks):.....$ 201.80
    AMMO BOXES
    2 ammo boxes (17" L X 8'W X 14 1/2" H)
    2 cans Blk hammer paint
    1 Clear coat
    Materials: $ 85.00
    Labor:......$ 74.00 (2 hrs @ 37/hr)
    Total (boxes)...$ 159.00
    **
    TOTAL PACKAGE (boxes and racks).........$ 360.80 (shipping is extra if applicable).

    I think you are up in the mountains so I could probably just meet you and save you the shipping. I could also give them to you unpainted if you like and you could save some money there as well.
    If you want anything else built custom, just let me know, tail racks , GPS mount,..whatever.....
    [​IMG]- Ron Grace- Arvada, CO.
    #17
  18. DDT Rider

    DDT Rider Been here awhile

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    Thanks for reply!
    The 1200 GSA rack on the left seems like it would be the challenge, as that rack bends around the muffler...

    ...and I have no welding tools/ability ;>
    #18
  19. PigPen67

    PigPen67 Ron Grace Jr.

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    Hi,.... too bad you're so far away!... it's really not a problem to cut out 2 parallel lines how to create a rectangular hole..... say about 5 inches wide... then cut a piece of sheet metal that's about 7 inches wide and the length of the rectangle, then push it into the slot and weld each side... don't underestimate yourself, you could do all of the prep work cut the slot and then the material, then just go to a welding shop and have them weld what you tell them to. You will have already done the hard part... so it shouldn't be very expensive.
    #19
  20. OPEN RANGE

    OPEN RANGE Runnin out of Time

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    pm and email sent
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