RotopaX One Gallon Tool Box

Discussion in 'Equipment' started by Hughes500Pilot, Dec 30, 2012.

  1. Hughes500Pilot

    Hughes500Pilot Adventurer

    Joined:
    Dec 25, 2012
    Oddometer:
    15
    Location:
    Anaheim, CA
    I posted this the other day and it was up for a short time. Then it just disappeared and I have no idea why. So, I'm trying it again. -Steve





    ----------------------------------------------


    I'm pretty new here, but I been lurking around for a few months. So for one of my first posts, I thought I would share how I turned a RotopaX 1 gallon Water Jug into a Tool Storage Box.


    To start off, RotopaX makes several fuel containers for motorcycles and off-road vehicles. Two things set these fuel cans apart from others. First, they are made very, very strong. Really, these are high quality fuel containers that do not leak. Second, they are made to firmly mount on to just about anything. This is due to their special mounting bracket. This bracket is lockable and is stackable so several fuel cans can be placed one on top of another and then locked in place.

    [​IMG]

    [​IMG]

    One product they have is their storage box / emergency kit. The box is the same for both versions, but the storage box is black and the emergency kit is orange. I think this is a great idea. You can mount a jug of fuel and spare tools in a very secure mount and have just about everything you need for the trail.

    [​IMG]

    [​IMG]

    Now here is the catch... The storage box / emergency kit is designed from their 2 gallon fuel jug. I think the 2 gallon size is a little too big for my needs. I have a Yamaha XT225 and I like the 1 gallon fuel jug better. But they do not offer a 1 gallon size storage box. So I decided to make on myself. Here is what I did...

    I started off with a standard 1 gallon RotopaX water jug. As far as I can tell, its the same as their fuel jug, just white in color and is $20 less expensive then the gasoline jug. Then I bought a 12 inch piano hinge from Lowes. I bought stainless steel, but you could use brass or zinc steel plated as well.

    [​IMG]

    [​IMG]

    At 12 inches, the hinge is a little to long, so I had to cut off 2 inches. At 10 inches, it fits perfect on the back of the jug. Don't worry about the hinge pin coming out, it is pinned in place.

    [​IMG]

    Next, I bought a pack of " Table Leaf Aligners" from Rockler Woodworking. They come in a 6 pack for $5. Since I was going to split the fuel jug in half, I wanted something to keep the two halves aligned together when closed. These turned out to work perfect. They are made to be mounted to a flush surface. They lock the two halves together in all directions. In the second photo you can see how they interlock with each other.

    [​IMG]

    [​IMG]

    Next I used a small saw blade mounted in a Dremel tool to carefully cut the water jug in half. There is a seam mark on the fuel jug, so it is easy to follow as you cut.

    [​IMG]

    [​IMG]

    [​IMG]

    The beauty of using the water jug it has a spout. This acts as a locking device when you close the tool box. Plus it keeps that side all aligned with each other. I was concerned the threads might not grip any longer because material is lost as you cut it in half. But, the threads are so deep, the cap locks down tight with no problem.

    [​IMG]

    Next, I marked and drilled holes for the hinge. Pretty simple.

    [​IMG]

    [​IMG]

    I then mounted the table leaf aligners. 4 holes and bolt it down. You can see how the aligners hold real tight.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Thats pretty much it. Here you can see the gas jug mounted below the new tool storage box. The hinge keeps the rear closed together and aligned. The water jug cap secures the left side and keeps it aligned together. And the table leaf aligners keep the right side locked in place and aligned. As for security, I bought the key lock mounting kit. Now when mounted on my motorcycle, the locking lug keeps the two halves pressed firmly together and the key lock prevents theft.

    I can fit a tube, tire irons, tools, a couple of space blankets and other things in there as well.

    Tell me what you think. -Steve

    [​IMG]

    [​IMG]

    [​IMG]
    #1
  2. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    6,159
    Location:
    Turning expensive metal into scrap
    Diggit
    #2
  3. chrome bandit

    chrome bandit Wide footed adventurer

    Joined:
    Oct 3, 2009
    Oddometer:
    305
    Location:
    Seattle-ish
    Nice job...well done! Easy to reproduce as well.

    One idle thought - what's your thinking on waterproof here? I'm not sure how well the seams will stay close despite the sound anchoring with the hinge and fasteners.
    #3
  4. GI_JO_NATHAN

    GI_JO_NATHAN Long timer

    Joined:
    Sep 23, 2010
    Oddometer:
    2,639
    Location:
    Middle GA .....Aparently....
    That's really awesome!
    Good work!
    #4
  5. DirtyDog

    DirtyDog Omnia mea mecum porto

    Joined:
    Apr 27, 2007
    Oddometer:
    8,986
    Location:
    Tulsa... it's OK
    Nice job, dude. Creative thinking with those table-leaf alignment thingys.

    I agree on the waterproofing question.
    #5
  6. Canuman

    Canuman Crusty & Unobliging

    Joined:
    Jun 21, 2008
    Oddometer:
    4,687
    Location:
    The Palace of the People, VT
    Well done. Very creative thinking. With a little more ingenuity, I'm sure you could waterproof the rig.
    #6
  7. Bokrijder

    Bokrijder Soyez sans que peur

    Joined:
    Aug 24, 2005
    Oddometer:
    321
    Location:
    Mile north of Turkey Point light house
    Looks like the factory offering is no better than water resistant, so at worst you're not too far behind the game with your mod project.
    Improving the mod level to highly water resistant would really put the icing on the cake.
    Good thinking and nice project.

    Bokrijder
    #7
  8. NCK

    NCK Been here awhile

    Joined:
    May 17, 2010
    Oddometer:
    481
    Location:
    Chicago
    sweetness

    Do you think you could have cut through a little higher up to make the bottom bigger and the top smaller?
    #8
  9. mark1150

    mark1150 Been here awhile

    Joined:
    Oct 10, 2010
    Oddometer:
    205
    Location:
    Wisbechistan UK
    Looking at it I think the handles would be the deciding factor as to the cut lines.

    Top job.
    #9
  10. S/W

    S/W Been here awhile

    Joined:
    Oct 21, 2003
    Oddometer:
    556
    Location:
    Massachusetts
    Seems like it would be just as easy to buy a cheap top box and get more volume for your money, and weather resistant seal. ?
    #10
  11. steve_k

    steve_k Long timer

    Joined:
    Jul 19, 2008
    Oddometer:
    1,068
    Location:
    Seattle area
    Nice work!
    #11
  12. joenuclear

    joenuclear Ride to eat, eat to ride... all roads lead to pie!

    Joined:
    Mar 16, 2007
    Oddometer:
    7,521
    Location:
    Fort Smith, Arkansas
    +1
    #12
  13. divimon2000

    divimon2000 Been here awhile

    Joined:
    Apr 16, 2011
    Oddometer:
    643
    Location:
    Lake Champlain, Vermont
    Very nice indeed!
    #13
  14. frog13

    frog13 Long timer

    Joined:
    Feb 10, 2007
    Oddometer:
    1,532
    Location:
    SW Ohio
    Probably just my computer,but your photo's cut-off about halfway through the "demo".:huh
    #14
  15. frog13

    frog13 Long timer

    Joined:
    Feb 10, 2007
    Oddometer:
    1,532
    Location:
    SW Ohio

    DISREGARD!....stupid computer is playing games, AGAIN!.
    #15
  16. gogogordy

    gogogordy Long timer

    Joined:
    Feb 25, 2009
    Oddometer:
    2,350
    Location:
    Winchester, Southern California

    Wheres's the fun in that?

    To the OP- frikking fine job! Props to the Rotopax army!
    #16
  17. squiffynimrod

    squiffynimrod maximum shrinkage

    Joined:
    Mar 23, 2010
    Oddometer:
    1,676
    Location:
    Flatskatchewan
    But a top box won't fit on the Rotopax mount.

    Would a couple of drain holes on the bottom address the water issue?
    #17
  18. G19Tony

    G19Tony Been here awhile

    Joined:
    Oct 14, 2011
    Oddometer:
    420
    Location:
    KLAS
    Very nice work. Find a thin rubber seal for that and it would be perfect. Good job. I always appreciate ingenuity. :clap
    #18
  19. lovias

    lovias Been here awhile

    Joined:
    Sep 10, 2006
    Oddometer:
    577
    Location:
    eastern Nebraska
    I am too cheap to buy box to cut in half but some of your ideas will be helpful in near future..:clap
    #19
  20. Bicyclist

    Bicyclist Been here awhile

    Joined:
    Feb 2, 2006
    Oddometer:
    555
    Location:
    Maryland
    Nice job. I like the alignment pin idea. If you can find some thin wall rubber hose, put a lengthwise slit in it and slip it over one of the cut edges. It might solve the waterproofing issue.
    #20