Toolboxes

Discussion in 'Equipment' started by Maoule, Feb 18, 2013.

  1. Maoule

    Maoule Been here awhile

    Joined:
    Nov 30, 2012
    Oddometer:
    646
    Location:
    KCMO
    I actually finished these last week but haven't had time to post. Frickin' work..
    Anyways...the particulars:
    '11 Adv. 990R;
    Happytrails SU luggage racks;
    Pelican 1550 panniers;
    stock exhaust.
    I didn't take enough intermediate pics of the process, so I'll try to explain in detail.

    Two 16" pieces of 4" aluminum square tubing, 1/8" wall thickness. I welded a cap on one end. I fabricated a cover from 20 ga. stainless. The hinge is 6mm stainless rod through 3/8" alum. tube (1/4" rod was too tight) with the 6mm shaft welded to 2 ears on the cover:
    [​IMG]
    To fasten the tool box to the luggage rack, I welded a pc. of aluminum angle 3/4"x1/8"x? (I don't remember the dimension, only that it fit between the alum. pannier pucks). The space provided by the 3/4" angle was a snug fit for the 3/4" Happytrails rack:
    [​IMG]
    The 3/8" aluminum tube on the cover was welded to the bottom of the toolbox after making sure of correct spacing for a rubber seal.
    [​IMG]

    The stainless locking latches were installed by welding the small side to the cover and bolting the other side to the box with 2 flathead 10-32 screws and locknuts. The entire unit was fastened to the luggage rack with four 10-32 machine screws countersunk into the 3/4" angle and threaded (and locktited) into the luggage rack. There's not a lot of meat in the tubing thickness of the rack, but I'm hoping with the snug fit, the screws won't vibrate out.
    [​IMG]

    I'm using a small master lock for security. I gave her flowers for Valentines Day...she should, at least, wash the bike for me :huh:rofl
    [​IMG]
    Here's a shot with the panniers removed:
    [​IMG]

    I painted the toolboxes with some Rustoleum hammered finish paint. I have a 21" tiretube and a small hand pump stored so far; my goal is to move the weight stored under the seat and glovebox to the rack-mounted toolboxes.
    Additional thoughts: I considered mounting the toolboxes to the panniers, but the additional hassle of removing the pannier and leaking potential in the pannier changed my mind. Also, some quick calculations show that these dimensions would hold almost 1 gallon of liquid:wink: Anybody have some thoughts on the feasibility of plumbing to the existing fuel system or adapting a quick removal setup? Also would this be safe/durable enough for fuel?
    #1
  2. Mr_Gone

    Mr_Gone The Lejund!

    Joined:
    Jul 18, 2010
    Oddometer:
    8,708
    Location:
    Mountain Home, AR
    Brilliant!!! Great job. :D
    #2
  3. bob393

    bob393 Been here awhile

    Joined:
    Dec 23, 2010
    Oddometer:
    394
    Location:
    Goshen, NY
    Nice work!
    #3
  4. Scott Baja

    Scott Baja el semental negro

    Joined:
    May 27, 2010
    Oddometer:
    232
    Location:
    Missoula MT
    Very clever, you should be proud! :clap
    #4
  5. bikerfish

    bikerfish flyfishandride

    Joined:
    Aug 18, 2010
    Oddometer:
    1,738
    Location:
    western pa
    where do we put our order in?!!
    #5
  6. Maoule

    Maoule Been here awhile

    Joined:
    Nov 30, 2012
    Oddometer:
    646
    Location:
    KCMO
    Too much customization for the mounting. Plus the making the lid and welding it to the box was a PITA. I do plan to dig deeper into making auxillary fuel tanks using the tubing;)
    #6