Making a Smuggler?

Discussion in 'The Garage' started by richarddacat, Jan 27, 2013.

  1. richarddacat

    richarddacat best jelly roll in town

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    Got it smoothed out,
    [​IMG]
    [​IMG]
    [​IMG]

    Been putting the lid off but it's time to figure out what I want. I could do just a flat flap or a cap with edges that go around the outside which would be easier to make water proof but make it larger.
    May browse around Lowes for some ideas. :scratch
    #21
  2. bete

    bete misguided adventurer

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    It's coming along good. bete.
    #22
  3. Worroll

    Worroll Been here awhile

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    Impressive! :clap
    #23
  4. DSM8

    DSM8 Where fun goes to die....

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    If you make the cap you could go with a nice peice of AL say .25" thick and have an O ring groove machined into it, that will make it water tight when bolted down. Still keeping the stream lined look your after.
    If you taper the edges down it will be even more refined, just overlap the opening by 1" giving you enough material for the taper past the O ring.
    #24
  5. richarddacat

    richarddacat best jelly roll in town

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    :clap
    I like that idea :thumb but things are hectic at work I need my star machinist to mill this groove, I'll keep your suggestion in mind and my first thought for a lid was a flat one. Actually made one out of wood but I'm going with something else for now.

    I've been running lid designs around in my head, simple ones that I can do in the garage and the hingeing of it has been hanging me up. I could easily covert to the aluminum flat cover later with what I've come up.
    The lid will hinge on the flat side next to the front seat. I really wanted it conspicuous and hated the thought of a door hinge being visible.

    What I'm going to do is use a lid that drapes over the sides and back and use a pivot point pin on the front right and left side. I'll make tabs on the lid where holes will be drilled through it and into the box. Maybe use a 13" length of threaded rod to be hidden on the inside and cap nuts on the outside? Might be hard to envision with my explanation but I'll probably glass it today and have some pictures later. I could have made it flat and still could later.

    The only thing with this lid is that it's going to make it look bigger so a flat lid like you described will still be on the burner. I could still make this lid a flat one without flanges so we'll see how it turns out. It's only fiberglas and time :rofl
    #25
  6. Grinnin

    Grinnin Forever N00b

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    I'm very impressed.

    For a lid, can you put saran wrap on top of what you already have so that your box becomes the form for the lid? I'm thinking the edges of the lid could drop down the sides an inch so gravity helps keep water out. You might be able to open up the access hole some too. (You also might be able to imagine better lids than I do.)
    #26
  7. Bounder

    Bounder ExternallyDisplaced

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    Looking good! Interested to see it finished.
    #27
  8. richarddacat

    richarddacat best jelly roll in town

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    I first covered the box with stretch wrap and since the top has a hole in it I covered it with a flat piece of cardboard. I thought I needed a lip to build an edge up so I took another piece of right-angle cardboard, slit it so I could form it and tape it down.

    Prior to my construction I thought it may be best to flip the edge over so I could fiberglas up against the box. This would have had a tighter fit for the lid but I forgot about that during my construction and realized it later after it was glassed. Oh well, it's less than a 1/8 thick. We'll see how it fits tomorrow and I might need that room for a foam edge???.
    [​IMG]

    Since I had good luck with the foil tape and paste wax I stuck with that.[​IMG]

    Drying as we speak,
    [​IMG]

    Considering a magnetic latch and not really concerned security.
    #28
  9. richarddacat

    richarddacat best jelly roll in town

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    :rofl we think alike. I am wanting to open the hole up too where I have maybe an inch from the outside edge. The hole I got is also not exactly square with the outside edge. I poked it in there just so I could get my hands in.

    Thanks for everyones comments, :clap this is a fun project and I enjoy doing it. I'm really not happy calling it a Smuggler though since Corbin has that name, I need to call it something else, a monkey, ass-hatch, back-buddy, litter box :D or something more original than Corbin's high dollar compartment. :lol3
    #29
  10. richarddacat

    richarddacat best jelly roll in town

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    My new top popped out,
    [​IMG]

    And it fit like a glove :clap
    [​IMG]

    I cleaned up the edges and figured where my pivot holes are going to be. I thought it may be best if the holes and pins rode on something more substantial than fiberglas so I JB Welded two washers where my holes are. Might see what kind of shoulder bolts we have at Ace Hardware for my pins.
    The 88 sticker in the back came off a sheet metal license plate holder, the sticker is what we use to use as registration. This piece is slightly recessed and is where my magnetic latch will be.

    [​IMG]

    I'll put a thin sheet of bondo on the lid tomorrow and smooth it out.
    Looks like paint time is not to far off. :rilla
    #30
  11. richarddacat

    richarddacat best jelly roll in town

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    OK, almost finished. Smoothing out the imperfections is taking some time, I gave a thought to painting it with a texture but that would cause too must wind resistance :rofl.
    Painted and sanded it twice to see and fill the rough spots.
    [​IMG]

    I'm using regular paint so I think I'll get some real primer that has some fillers in it.
    [​IMG]

    The lid worked out good, haven't got the latch just the way I want it and I was thinking of coating the inside with some plastic dip.

    Also not sure on the color yet, I've got a blue paint that's pretty close to stock or I may just go with black, flat black if I can't get the surface just right. either way I think it will look good in a picture and at a distance as it sits now. :lol3

    [​IMG]
    #31
  12. smoky

    smoky Been here awhile

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    That's a terrific looking project!

    Well done. :clap
    #32
  13. Grinnin

    Grinnin Forever N00b

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    Your photos don't show anything that needs a primer with fillers. Those reflections are "fair" as they say in the boat shops.

    And I like the black. If there IS an undulation somewhere it'll disguise it all the more as a second seat. (You could paint faux quilt stitches on top.)
    #33
  14. Jnich77

    Jnich77 Been here awhile

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    carpet the inside, keeps things from rattling and sliding around.
    #34
  15. richarddacat

    richarddacat best jelly roll in town

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    :hmmmmm I was thinking again :jack, what if I sprayed the lid with plastic coat? Then I would have a slip resisitance surface to set my helmet, camera, glasses or a bottle of water...:hmmmmm
    And what if I used that "hammered-look" paint to hide any imperfections....:hmmmmm

    :hmmmmm carpeting inside?

    Going to be too nice to be called a litter box :rofl
    #35
  16. richarddacat

    richarddacat best jelly roll in town

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    Weather has been a little funky but should be warm enough to paint tomorrow. :clap

    Looks like I'm going to have less than $150. in my little project, pretty good consider the alternative Smuggler from Corbin. :evil
    #36
  17. Grinnin

    Grinnin Forever N00b

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    You mean that you could have spent just a little more to get a professionally-made and cosmetically-flawless one?

    And give up the knowledge you've gained during this project? And give up the sense of accomplishment you'll probably have every time you see it? And give up the confidence you probably have to tackle similar or more complex projects?

    Regardless of what you saved I think you won by tackling it yourself.

    Oops. Rant off. /RANT Stop. OK, what's the command for this?
    #37
  18. 1 Wheel Drive

    1 Wheel Drive Flatus Antiquous

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    That depends what you consider "a little." A Corbin Smuggler costs $800 plus shipping new, so if you consider $650 as a little, then yeah he could have done that.

    And the Smuggler is known to have a relatively small capacity (11.5 liters, not all of which is useable) and also not be watertight. I think Richard's seat-box is what Corbin should have offered all along. I'd buy one. Nice work!
    #38
  19. concours

    concours WFO for 41 years

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    That would be a Russell Day Long seat, http://www.day-long.com/ arguably the best in the business. Once past the bar-hopping stage of motorcycle usage, "ugly" is not really concern for a seat. of course, it lacks the blue suede flames sewn into many MoCo and Corbin seats... but hey, there is always a prettier bike parked outside the tavern :freaky
    #39
  20. richarddacat

    richarddacat best jelly roll in town

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    Done....except maybe for trying different colors, try that with Corbin :lol3
    The "hammered" doesn't look hammered like it does on the cap but since I had three days to finish out any defects it really didn't matter. Smooth as a baby's ass. Only big flaw I had is on the lid hiding under the Yellowstone sticker.
    [​IMG]

    Also ditched the magnetic latch and went with a simple cabinet latch.
    [​IMG]

    Found out that it will hold 2.5 gallons of water or 6lbs of cat food. Looks like at least a six pack and small bag of ice would also fit nicely. :1drink

    [​IMG]

    May paint it blue or black, the blue paint I had that was Galaxy Blue is a colorshift paint which changes colors on different angles, not so sure about that. :ymca


    BTW, haters are going to hate, life's too short, move on. :wave
    #40