Rotopax Mounts for my 990 Adventure

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Hondo, May 30, 2012.

  1. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    I wanted to mount 2 Rotopax fuel containers on my 2011 990 Adventure Dakar.

    The requirements were -

    - the mounts had to be strong
    - independent of the Gobi tail box
    - independent of the panniers

    When looking at the Rotopax website, I found that they offered the one gallon Rotopax & their steel "L" mounting bracket as a kit. I ordered two of the kits -

    [​IMG]

    The "L" bracket is very strong and has 2 positions to mount the Rotopax vertically and many mounting holes on the bottom of the bracket for it's mounting. The weight of the Rotopax and their mounts is listed as 5.8 lbs. That comes to 11.6 lbs for the 2 sets. Add 13.4 lbs for 2 gallons of fuel and the total comes to 25 lbs total.

    My plan was to create a strong mount that would bolt to the stock KTM/Gobi tail box mount, and the "L" brackets would mount to it. That way the tail bag gould be removed, installed or opened with the L brackets in place.

    So I laid out a 5 bolt pattern to secure the 1/4 inch thick mounting bar & drilled the holes out -

    [​IMG]

    Then I positioned the bar underneath the rear rack and transferred the holes to the bar mount with a Sharpie -

    [​IMG]

    Here the mount bar is temporarily mounted to the rear rack -

    [​IMG]

    Then I installed the Gobi tail box -

    [​IMG]

    Then I positioned the "L" brackets on the bar and marked their hole locations -

    [​IMG]

    I then drilled out the mounting holes. You can also see that I cut out a notch in the rear of the bar. This allows the Gobi tail bag's mount & lock access to the rack.

    [​IMG]

    Then I eased all of the sharp edges with a fine file, eased the holes a bit with a countersinking bit, and cleaned it off in perpetration for paint. Here it is air drying after I painted it with satin finish enamel -

    [​IMG]

    Mounted to the rear rack with stainless steel button head screws, washers and nyloc nuts -

    [​IMG]

    [​IMG]
    #1
  2. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    Then I mounted the "L" brackets to the bar -

    [​IMG]

    With the Rotopax installed -

    [​IMG]

    A few shots with the Gobi tail box -

    [​IMG]

    [​IMG]

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    With the Gobi box open -

    [​IMG]

    [​IMG]

    Overall I am very happy with this mod!
    #2
  3. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    With the Mermite Panniers installed -

    [​IMG]
    #3
  4. Yellow Pig

    Yellow Pig Allergic to Asphalt!

    Joined:
    Oct 28, 2004
    Oddometer:
    7,707
    Location:
    Kalifornia
    Sure puts a lot of weight up high and back?! :huh
    #4
  5. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    If you think that 25 lbs a lot of weight, I guess you could say that. When you consider how much a passenger or other gear strapped onto the back weighs it's really not that much on a 461 lb bike.

    The beauty of the Rotopax is that I need only install them when I feel the need for extra gas.
    #5
  6. BUMOT

    BUMOT Adventurer

    Joined:
    Nov 8, 2010
    Oddometer:
    62
    Location:
    Bulgaria
    Exellent job!:clap
    #6
  7. v8toilet

    v8toilet Nothing to see here.

    Joined:
    Jul 11, 2005
    Oddometer:
    1,738
    Location:
    Northwest U.S.
    When you consider the leverage of the 25 lbs on your subfame that far aft it is significant.

    Nice work on the install.
    #7
  8. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    The weight is on the pannier rack & tail rack, so the weight is distributed to the entire subframe (not in one place). I would guess that it is less stress than a passenger.
    #8
  9. 4corners14

    4corners14 Been here awhile

    Joined:
    Oct 3, 2008
    Oddometer:
    701
    Location:
    Seattle
    Well thought out and nicely finished! If that weight creates a problem......then my 990 should have already broken in half :lol3 :rofl:rofl:rofl
    #9
  10. rwavaktm

    rwavaktm Been here awhile

    Joined:
    Apr 20, 2010
    Oddometer:
    180
    Location:
    Braselton,Georgia
    Nicely Done. I am still pondering how I want to carry extra fuel. I like your design.
    #10
  11. EatinDirt

    EatinDirt WannaB Thumpin

    Joined:
    Aug 22, 2010
    Oddometer:
    19
    Location:
    The Desert
    Nice and clean I think they turned out Great!!!:clap
    #11
  12. MrSandman818

    MrSandman818 INaVANdownBYtheRIVER

    Joined:
    Dec 29, 2009
    Oddometer:
    853
    Location:
    El Paso, Republic of Texas
    Nicely done! I just did th same thing except I mounted them directly to my top gobi. I don't want be pushing my bike I'm Canada this weekend!
    #12
  13. SF_Rider

    SF_Rider Been here awhile

    Joined:
    Feb 2, 2011
    Oddometer:
    450
    Not sure how practical it would be or difficult.

    Seems like a bit of weight up high and to the side. Would be cool if there was a way to rotate the tabs/cans to set where the passenger would sit. One tab would be able to slide in and out so the packs would be in line taking up the passenger spot when not traveling with someone keeping the weight lower and more centered.

    Looks like a great setup, almost as good as my safari tanks.....
    #13
  14. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    Not as convenient, but less expensive.
    #14
  15. SF_Rider

    SF_Rider Been here awhile

    Joined:
    Feb 2, 2011
    Oddometer:
    450
    I use my bike for too many things. I often will commute 100-200 miles in a day. The fuel stops were killing me

    #15
  16. nathanoj

    nathanoj n00b

    Joined:
    Apr 21, 2008
    Oddometer:
    4
    Excellent work! I love the idea! What are the dimensions of the bar that goes underneath the rear rack?
    #16
  17. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    18 3/4 X 4 1/2 X 3/8 inches.
    #17
  18. airarrazaval

    airarrazaval n00b

    Joined:
    Jul 5, 2011
    Oddometer:
    6
    Location:
    chile
    Nice job Hondo!
    I live in Chile and I have my "issues" with the Gobi tail box in dust trails. I folded it 2 times and with lightweight. I imagine with the Rotopack will be worse ... Did you tried it on dirt roads?
    #18
  19. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,065
    Location:
    Front Range, CO
    Yes, I've ridden the bike with the gobi tail box & the rotopax full of fuel on dirt roads, but not on any extended length rocky trails.

    I have ridden very rough terrain with the Gobi tail box without any issues.
    #19
  20. JustPlainDave

    JustPlainDave Tubeless Adventurer

    Joined:
    Mar 11, 2009
    Oddometer:
    202
    Location:
    Sarasota, Fl
    It's kinda sad seeing your old green steed in the background of your pics.
    She seeing any action since you got the 990?
    #20