How to Mount Top Box

Discussion in 'Equipment' started by Gonzoso, Jan 9, 2013.

  1. Gonzoso

    Gonzoso Been here awhile

    Joined:
    Sep 2, 2012
    Oddometer:
    179
    Location:
    Pocono Mt.s PA
    I'm putting a Seahorse 540 case onto a 2012 KLR 650 stock rear cargo rack. The plan it to plan out 4 holes and drill so I can still access the tool kit.

    I will put silicone sealant around the hole as I tighten it up so I can better water proof it. I'm putting panniers on and probably won't haul much weight in this, 10-15 pounds at most I figure, but mostly clothes or rain gear or my lunch pail for work.

    Here is a diagram of my idea for mounting it.
    [​IMG]

    I was thinking that using a rubber bushing between would help isolate the box from the bikes vibration and shocks offroad, although it will be on road 80-90% of the time I do like to play in the dirt.

    Does anyone have any suggestions or input on how to mount the box? What kind of hardware I should use? I'd like to do it well, but not make it overly complicated. I'm planning on putting it on semi-permanently, maybe use wing nuts instead of hex heads on the end of the fastener inside the box.

    I'm also planning on putting some footman loops on top of the box.
    #1
  2. Grinnin

    Grinnin Forever N00b

    Joined:
    Dec 10, 2005
    Oddometer:
    2,985
    Location:
    Maine
    I have an '01 so I don't know the shape of the underside of your rack plastic.

    I wonder, though, if you couldn't flip that bolt and use a flanged button-head hex (Allen) bolt to keep the inside bottom of your case a little kinder to the contents. I used Tee nuts inside my cases and it's darn flat, but a bit fiddly to install. With big stainless fender washers too.

    I also mounted my top-box directly to my rack plastic. When there was a bit of play it was amplified by the box so it moved far more than the rack's vibration.

    Stainless for everything.
    #2
  3. p0diabl0

    p0diabl0 Been here awhile

    Joined:
    Feb 25, 2011
    Oddometer:
    577
    Location:
    San Diego
    I doubt the rubber bushings are necessary - I have an old Givi E45 that's bolted to my SW Motech rack - no problems, and that plastic is much thinner than a Seahorse case.

    As to the wingnuts I tried that out too then quickly realized I never wanted to take it off.
    #3
  4. FlowBee

    FlowBee Just me.

    Joined:
    Oct 11, 2004
    Oddometer:
    5,759
    Location:
    Stasis.
    When I bolted my Pelican 1500 to the OEM rack on my DR I used large stainless fender washers and rubber fender washers underneath. I slathered the bolt threads (head is inside case) with silicone sealant first and then used locknuts on the other end. Six bolts altogether. Works fine so far. No water inside.

    I agree with p0diabl0 - you probably don't need the rubber bushings. Just use large enough fender washers (eg 20mm or larger) to spread the load on the plastic wall.
    #4