Cheeep hard case project

[Terry Lee]

My whole life at the moment revolves around a planned trip in late July. Extra fuel canisters etc. I also need to carry the necessity's of life on the small confines of my bike. The cost of travel luggage, to this newby, seems excessive. I found these two items at a Home Depot style of store. Sturdy and inexpensive. These are toolboxes in another life. I checked and the decals will all come off:)
https://lh3.googleusercontent.com/-x1ipwHl1iTU/VV0z_WLYYGI/AAAAAAAAHvA/idXufk5tgc4/s172-no/FM2.jpg.jpghttps://lh5.googleusercontent.com/-DSZzDnM7wos/VV00AAJgTaI/AAAAAAAAHvE/W2TR3HiWy6E/s172-no/FM1.jpg.jpg

After examining under the rear cowl area, I located the four bolts that attach the grab bar and the rubber dampers for the seat/cowl. They all thread into a substantial frame member.
https://lh6.googleusercontent.com/-omWdlUeHPyI/VVzATmmI0vI/AAAAAAAAHuY/iXnohaSz5Uc/w972-h547-no/IMG_2327.JPG

I'm using Corplast to determine size and bends. I'll reproduce this in aluminum sheet.
https://lh6.googleusercontent.com/-gAPIz6jpcvs/VVzAUBagArI/AAAAAAAAHug/CSwXsOIw9y4/w972-h547-no/IMG_2328.JPG

Just trying to figure out spacing using cartons I had sitting around.
https://lh4.googleusercontent.com/-6OA0W9jA1M4/VVzAUp8tgSI/AAAAAAAAHuk/ynpkaSroaz8/w970-h547-no/IMG_2332.JPG

[SIII]

I doubt a single sheet of aluminum (american spelling for you ;-) )will be strong enough to take the weight of 2 of those boxes. It would end up supported by the rear fairing. Plus i would image it would fail on the bend after about 500 miles due to flexing and subsiquent work hardening.

You need to create a 3D structure to take the weight and stop the flex.

[yorkie_chris]

Lot of bending moment on that ally mate.

Knock something up out of tube with some sturdy tabs IMO. Maybe onto the pillion peg hangers as well

[Terry Lee]

I doubt a single sheet of aluminum (american spelling for you ;-) )will be strong enough to take the weight of 2 of those boxes. It would end up supported by the rear fairing. Plus i would image it would fail on the bend after about 500 miles due to flexing and subsiquent work hardening.

You need to create a 3D structure to take the weight and stop the flex.

I have no intentions of leaving it flapping in the breeze. Plans are to tie the forward edge into the passenger foot peg. The aft end will either be triangulated with bracing or a piece running from left to right. I'm very familiar with aluminum/aluminium and its failings. When I built my airplane I constructed a number of brackets and braces that fastened to the engine. Over a couple hundred hours, every item failed or showed cracks. Especially any bend that had been cold worked. All my beautiful powder coated handiworks replaced with steel.

I've had really good luck with the alloy I'm planning on using. I've used it for two recumbent seats that have shown no sign of failure taking the mass of my bulk on over 3000 kms. Bend radius is key. Here's an example of one seat.
https://lh3.googleusercontent.com/-kW7nCKUbZNY/VV3nbfGZBfI/AAAAAAAAHvY/ykUVi7JHBio/w789-h591-no/under%2Bseat.jpg

And another example...
https://lh5.googleusercontent.com/-hGOo-kng47E/VV3ql4JqafI/AAAAAAAAHvk/2a147lovgjo/w1044-h590-no/IMG_0535.JPG

If anyone's interested, here's the simple tool I used, and will use to do the folding.
JPbgyo6Ltz4

The black recumbent is a one of a kind double, pivoting, crank/steer/brake with your feet Python derivative angry machine that I've entitled "KrankiKobra". It has helped create new neural pathways in this aging brain:D
https://lh5.googleusercontent.com/-YR36N1aJe_g/VV3sdm9UFoI/AAAAAAAAHvw/LnbNHCxXck4/w943-h591-no/Terry%2BJantzi%2Bhands%2Bfree.jpg

[Bibio]

ooohhh dear, porn for Jayne :-)

[Terry Lee]

ooohhh dear, porn for Jayne :-)

Have I committed some forum faux pas?

[SIII]

If yer building planes, you know what your doing then. Just from the image it looked like you were going to use just a sheet ! LoL.

Good luck with the build, keep us up to date with progress

[garynortheast]

Far from it but you may find Jayne turning up here and getting a bit excited about the recumbent.

[SIII]

You were getting Terry excited, a picture of him on a bike classed as 'Porn', maybe he thought the limey wimen were into rigger glove wearing mature gentlemen !!! RGWMG as it is now called ;-)

[Terry Lee]

If yer building planes, you know what your doing then. Just from the image it looked like you were going to use just a sheet ! LoL.

Good luck with the build, keep us up to date with progress

I should have added that this is a real time work in progress. Like all my projects, there will be two steps ahead and one back. Mistakes, and design changes will happen on the fly:)

I just picked up a 11" x 48" piece of 5052 .080" piece of alumin/ium/um (wise guy smilie) to form tomorrow. I leave for my stupid evening shift shortly.

BTW, I will use a mixture of metric and imperial measurements. Canada never had the cajones to go all the way. But I do use proper English spelling for everything except 13Al. Colour, neighbour, odour etc;)

[Terry Lee]

You were getting Terry excited, a picture of him on a bike classed as 'Porn', maybe he thought the limey wimen were into rigger glove wearing mature gentlemen !!! RGWMG as it is now called ;-)

Yup, excited. If anything I do can be considered porn, my day/year is made.

[Jayneflakes]

ooohhh dear, porn for Jayne :-)

Hell yeah! :D

Have I committed some forum faux pas?

Hell no! ;)

Far from it but you may find Jayne turning up here and getting a bit excited about the recumbent.

I built my own recumbent a while back with a friend of mine and it was a wild ride. Unfortunately I got the head angle slightly wrong which resulted in an alarming speed wobble at anything above 10MPH!

I love recumbent bikes, no really I do. Years and years of Mountain biking and then some rather aggressive surgery has worn out parts of my body that I need to ride my push iron. A recumbent was the answer and so as an experiment I set about making one with the help of a good friend who is a professional welder. I tried welding once and made such a hash of it, I nearly set my self alight!

I am greatly interested in the twin pivot frame, does it handle similar to the twin pivot clown bikes that were popular in the late 90s?

More recently I discovered Cruzbike (http://www.cruzbike.com/recumbent-bike)s, and fell in love with them. Sadly we have no importer (well this was the case when I contacted them) that will bring them to the UK. They now offer a three wheeled device and it looks very clever, but again no chance of getting one in the UK!

Anyway, yeah, love the bike. :D

[Bibio]

cruzbikes.. how much!!! jezzzuzuuzzzzz my mate could knock those out no problem. how the hell is something so simple so bloody expensive :confused:

[Terry Lee]

Hell yeah! :D

I am greatly interested in the twin pivot frame, does it handle similar to the twin pivot clown bikes that were popular in the late 90s?

:D

The head angles were key as well and I made several adjustments. Small changes in angles made a huge difference in stability vs steerability. It was that compromise thingie. The effort was more an experiment and artistic effort rather than practical. Translation... it rides like a piece of %$#@. It did attract some attention from a local documentarian (https://www.youtube.com/watch?v=93NgduGk6lM) though. There's a number of videos on my channel chronicling various levels of success. In the first ride attempt below, there's evidence of tooth marks on my forehead where the ghost ring got caught on my wire wheel. When that happens, an object can rise up and smite you, even though wearing a face shield. This was the night before the big ride day. This machine is quite evil and will bite you at any opportunity. We have formed an uneasy truce and I can ride without injury if I don't relax my guard.
DUU9ZNzJAlw

Here's some recumbent porn of the KrankiKobra and a much safer trike I built.
https://lh3.googleusercontent.com/wYcEBwIqfI8ZJJK9paYlMYT-F-XAJvogRCtCmmdLhQA=w368-h207-p-nohttps://lh3.googleusercontent.com/SPJ6gW8rUlFHQqu8QeZPSgBj-IW6_1IoEqqXqIQjfdw=w368-h207-p-no
https://lh3.googleusercontent.com/tKYmQgR1FgRkt1aBr-MYO1KSip9Gv6tTAA_9uCN97Ik=w311-h207-p-nohttps://lh3.googleusercontent.com/2kJyyi1D8BaRN5OGJLV-dNzcXMJEZWYvHJpXTScm0Oc=w311-h207-p-no

I've put a lot of miles on the trike in the past 3 years and still brings a smile to my face. It handles like a high performance airplane. And old men have a hard time falling off or out of it. But, if you attempt a tail slide in front of several brothers and sister-in-laws, you may end up with the trike on top of you with three broken ribs... two days before a Dominican vacation:crutches:

[yorkie_chris]

When I built my airplane...

Ace line to be able to use in any DIY discussion! I salute you!
To have survived several hundred hours of operation all the more so.

Any more details on the plane?

Chris (DIY rebreathers and other diving equipment...)

[Terry Lee]

Okay, back on topic. The 5052 AL I picked up yesterday is friendly to forming, with a big enough lever. A simple tool I built for forming my recumbent seats consists of two 1.5" tubes fixed into a two handled frame. I had to refresh my bend math for starting at the proper offset. So far I have $20CAD into this project and I didn't want to screw up. It actually worked out pretty close.
https://lh6.googleusercontent.com/-AIGsLuSWjRg/VV9lCyDJreI/AAAAAAAAHww/wtwPAG-TX6k/w1044-h588-no/IMG_2339.JPG

It fits on the bike right where I want it. I plan on raising it up about 1-1.5"s so the top box will ride further aft. The widths of the toolboxes are a tad over 19", so it will ride over the rear tail piece. I have numerous hard points to tie into, and haven't yet made a decision. One of the design criteria I have is to make no structural changes to the bike and to allow for complete install or removal in a matter of minutes. Have I mentioned that I'm a extreme lazy individual? I would rather spend time drinking beer than performing droll tasks. Initial dry fit looks good.
https://lh6.googleusercontent.com/-GY9vJiZN-eU/VV9lDXWCbNI/AAAAAAAAHw8/8Mf7Le6Tn6k/w1044-h588-no/IMG_2340.JPG

https://lh4.googleusercontent.com/-U4m-M8gqnV8/VV9lEGO09LI/AAAAAAAAHxA/qhJKIvoeSyk/w1044-h588-no/IMG_2341.JPG

This weekend, I'll make the big purchase. The two side cases are $34CAD each and the top box is $45CAD. Projected fittings cost and incidentals added should bring the total damage to aprox $160CAD. Plus a thousand hours of free labour.

[Terry Lee]

Ace line to be able to use in any DIY discussion! I salute you!
To have survived several hundred hours of operation all the more so.

Any more details on the plane?

Chris (DIY rebreathers and other diving equipment...)

An old web page here (http://www.iwantarocket.com/rv6/).

[BRAG ON=] I flew it over thousand hours in four years. Set a number of world speed records. I think I posted a link to an Arctic flight in another post. [/BRAG OFF]

Absolutely the best homebuilt aircraft in the world. Many examples in the UK.

[Terry Lee]

Currently $147CAD into the build. Two side cases and one upper. Unfortunately, the upper is about .25" too shallow to secure my helmet. In an ideal world,where everything I see is rose coloured and the birds are singing on Snow White's shoulders, the whole assembly would install and remove the same as the pillion pad/rear cowl. I'm not sure I can do that with enough security. But, darnit, I'll try. How cool would that be? Here's the taped up progress so far.
https://lh6.googleusercontent.com/-ehtWm7_sFUw/VWEGSqdYMqI/AAAAAAAAHx0/1AXBIIINHPk/w1044-h588-no/IMG_2351.JPG

[Terry Lee]

Later that weekend...

I need to space the AL sheet up a tad so no rubbing occurs on the nicely finished factory panels. I had some copper tubing that I cut into 1" segments.
https://lh6.googleusercontent.com/-46WTe2C1Ejs/VWInGsH2YcI/AAAAAAAAHzY/3OFvyywbZzk/w1043-h589-no/IMG_2352.JPG

I know the advantages of using anti-vibration mounts, so I found some rubber ends that I punched a hole into. The two forward rubber pieces need to be slightly shorter than the aft ones. I've always had good luck spinning things in my hand drill against sharp edges, in this case a running band saw blade.
https://lh6.googleusercontent.com/-07sMFvRLwOo/VWImuyQI8fI/AAAAAAAAHyg/0YBNt2MfvHk/w1044-h588-no/IMG_2353.JPG

Here's the spacers and their new home.
https://lh5.googleusercontent.com/-OKKotHg6Z3Y/VWImvQsKTgI/AAAAAAAAHys/pN-sFp_bgzE/w1044-h589-no/IMG_2354.JPG

https://lh3.googleusercontent.com/-r9R_dnTz9z8/VWImv1Le6mI/AAAAAAAAHy0/5i2r0ruL0NU/w1044-h589-no/IMG_2355.JPG

continued on the next post...

[Terry Lee]

...continued from last post

With the aluminum sheet installed, the rails for the upper box can be located. These will be riveted on with lots of aircrafty lightning holes drilled.
https://lh4.googleusercontent.com/-Dl9gzjv7rfI/VWImwG1KXvI/AAAAAAAAHy8/R5arnjDnYWY/w1044-h588-no/IMG_2356.JPG

The upper box will have the option of being slid fore and aft. I'm not sure if that's useful or not. If anything, it allows me to adjust the CofG:p

This is close to the final placing of the upper and side boxes.
https://lh4.googleusercontent.com/-EPZW3Spx_Xc/VWImxNwpIqI/AAAAAAAAHzM/F8t6fpouQFA/w1044-h588-no/IMG_2365.JPG

https://lh5.googleusercontent.com/-gW8V2MemrTM/VWImxn87D0I/AAAAAAAAHzQ/ai7j65mtLvE/w1044-h590-no/IMG_2366.JPG

[Terry Lee]

The general shape and size has been determined. It's time to add some structural members to make it into a box section. Since I don't have accurate tools and my skill set has limits, I always cut big and trim to size, always leaving room for adjustments. I need to bend up an inner member that matches a slightly compound angle.
https://lh6.googleusercontent.com/-zv05KMMN778/VWNN6WH078I/AAAAAAAAH4I/BIMLvKHzNRc/w1044-h588-no/IMG_2371.JPG

Using a multiple minor, angled bends radiating from a centre line, I was able to shrink or expand the inner brace to match the outer mount. Notice the excess material begging to be trimmed.
https://lh4.googleusercontent.com/-MMNhru50MyU/VWNN6lnT4kI/AAAAAAAAH4M/A3iBHjRXbQw/w1044-h588-no/IMG_2374.JPG

After initial trimming, it looks almost ready for flight. Any woodworking hand tools can be used with aluminum, with care and with eye protection. Depending on the speed of the cutting tool and the flinging ability, bare skin protection as well. Lot's of hot chips.
https://lh4.googleusercontent.com/-LFSZ_UkkbfA/VWNd9l8J8bI/AAAAAAAAH4c/qcm0RYPg2zs/w1044-h588-no/IMG_2378.JPG

All boxed in. An anti-racking brace tie in point will be needed. My initial thought was the rear foot peg, and that still is the best candidate.
https://lh6.googleusercontent.com/-Ovx_vwZfwIM/VWNeBUg-v5I/AAAAAAAAH4k/VUA4ui0WDJQ/w1044-h588-no/IMG_2377.JPG

[jambo]

Just a thought here, I believe the rear suspension travel is the best part of 130mm from fully extended to compressed by the time it gets to the rear axel, and thus, the tyre. With luggage and / or a pillion you may find you're using most of that even if not pressing on.

It may just be the photos but I'm not sure if that bottom brace gives you that kind of room?

[Terry Lee]

Just a thought here, I believe the rear suspension travel is the best part of 130mm from fully extended to compressed by the time it gets to the rear axel, and thus, the tyre. With luggage and / or a pillion you may find you're using most of that even if not pressing on.

It may just be the photos but I'm not sure if that bottom brace gives you that kind of room?

Good point. I was concerned as well. I'll admit I didn't do my research for total travel. I sat on the bike and bounced up and down as hard as I could to see if I could make it touch. Not mathetific in any way, but I was satisfied. It look like I have about 100 mm at the maximum point. Fortunately, no passengers will be riding when decked out in full gear.
https://lh4.googleusercontent.com/-JU6fBj2RiQM/VWR0sMDyUDI/AAAAAAAAH5Y/0CoItaOtTAY/w1043-h589-no/IMG_2379.JPG

[ophic]

If anything, it allows me to adjust the CofG:p
You can have a "wheelie monster" setting :twisted:

...my skill set has limits...
not many!

[Terry Lee]

Just a thought here, I believe the rear suspension travel is the best part of 130mm from fully extended to compressed by the time it gets to the rear axel,

And that's why we form communities. Even with you guys and gals across the pond:smt008

A simple fix. I just rotated the brace up at the tail end to give me 124 mm clearance. I don't plan on riding where I need that travel. So now I have two extra holes, for weight reduction of course.
https://lh4.googleusercontent.com/-900606dXeu8/VWSqHj2DKAI/AAAAAAAAH5s/1jFQAOrTfE0/w1044-h588-no/IMG_2383.JPG

As an after thought, I folded the rear footpegs up and dropped the rack/saddle thing over them. Pure serendipity. The entire structure became rigid. The racking problem just went away. I love when a plan comes together, even by accident. My wife says it's a golden horseshoe. I'm going to have to adjust the inner brace out somewhat so that I can slide some anti-abrasion material over the footpegs. Read garden hose.
https://lh6.googleusercontent.com/-aS51zcfesls/VWSqIPvIgBI/AAAAAAAAH50/RApWK4ZxWcM/w1044-h588-no/IMG_2384.JPG

And to prove thats it's symetrical...
https://lh4.googleusercontent.com/-jE-pVa9yzV4/VWSqIiaJ3WI/AAAAAAAAH54/pywVRJ_JyiE/w1044-h588-no/IMG_2385.JPG

Finally on to permanently mounting the side cases. I have some "off the shelf, shelf hardware" that I used on my trike panniers. They're cheap and strong and click into place nicely. I want this entire project to be complete within one week. I'm close.

[Jayneflakes]

I love your ingenuity, as such I applaud your efforts and I fully expect to see you marketing a whole kit very soon!

I may have colour matched Oxford soft panniers, but they do not look as cool as these. Out of interest, the other half has an old Kwak GTR and the hard panniers on that can take the weight of the bike if it falls over. How strong are your boxes here?

[Terry Lee]

I fully expect to see you marketing a whole kit very soon!

I've tried marketing several of my inventions. It becomes very tiresome and I quickly lose interest and usually great piles of money:( Always looking for partners though. I think my most most successful endeavor may have been the RV Rocket Steering Link. Google friendly.

I may have colour matched Oxford soft panniers, but they do not look as cool as these. Out of interest, the other half has an old Kwak GTR and the hard panniers on that can take the weight of the bike if it falls over. How strong are your boxes here?

That is something I never considered. They are toolboxes with industrial heavy clasps. They lock together when closed with a female/male connection on the edges. I'm NOT going to knock my SV over to test! I'm not familiar with the weight of current hardcases, but these seem very light. I will do a full weigh in when everything is complete.

[jambo]

I love it when a plan comes together! Looking very nice there :)

[yorkie_chris]

Mate don't mess about.

There will be a time when you use full travel. That bump when there's a bit of a rise in the road and you're on the gas?

The suspension must be free from top out stop to bump stop, no excuses.

See the same with idiots fitting tail tidies that then get the number plate eaten by the wheel "oh I'll just wind the preload up harder" ... ffs...

[Terry Lee]

As mention previously, I'm using off-the-shelf-shelf-hardware. The clips will mate when placed opposite to each other. I've never figured out what their real purpose is, as I've always used them for other things.
https://lh3.googleusercontent.com/-XO1VWVOzKjs/VWX2xIOLm9I/AAAAAAAAH6M/DTStZ29snR4/w1044-h589-no/IMG_2386.JPG

On many projects, I've had really good luck using high density polyethylene or UHMW or cutting board material. The beauty of this material is that an undersized drilled hole will allow a screw to self tap into the piece. It locks and resists loosening. It grabs so well that one can mash the head of the screw if not vigilant. I've found it works equally well with fine or coarse threads. I've mounted two lateral pieces on the back of the tool box and screwed the shelf clips to it.
https://lh3.googleusercontent.com/-er3RSEBuQEw/VWX3JlIJTHI/AAAAAAAAH6c/sMsPWcw0nbs/w1044-h589-no/IMG_2391.JPG

I blind drilled the holes from the back side and screwed it in place with some stainless screws. I'm not sure if I'll install an additional metal reinforcing strip here or not.
https://lh6.googleusercontent.com/-_IvUbBLdTuo/VWX2yLU0XzI/AAAAAAAAH6U/lc_LCKD-2Rw/w1044-h588-no/IMG_2388.JPG

Four matching clips are screwed to the side panel of the saddle mount. The opposite orientation of course. One just lines up the clips and everything clicks into place. I'm going to fashion some sort of restraining clip or lock so that when I hit that maximum suspension travel event, the boxes don't depart for lower earth orbit:) The rear corner of the right box is about an inch from the rear portion of the muffler. I have enough room and a location to mount a heat shield if needed. This is the final placing of the upper and side boxes.There is room forward of the upper box to place a duffle bag across and resting on the side boxes.
https://lh4.googleusercontent.com/-Te26Xfj5Rpo/VWX3Sn4ZJ7I/AAAAAAAAH6k/I1CV28Jp48o/w1044-h588-no/IMG_2392.JPG

Final steps to completion are:
Mirror the left side box.
Trim, drill aircrafty lightning holes, and rivet the top box mount rails.
Mount the top box to the rails.
Create some kind of locking mechanism.
Disassemble, cleanup, adjust and powder coat the aluminum parts.
Test the crap outa it.

[Geodude]

Looking good :)


Clips look like picture or mirror hangers

[yorkie_chris]

HMWPE is great stuff, good enough for joint replacement bearing material :)

[Terry Lee]

I hadn't included a photo of the side mounts with the luggage removed. Ugly as sin. Some may say, "in its naked ugliness, there's beauty in its utility". It's as ugly as sin.
https://lh3.googleusercontent.com/-pcsIM59od14/VWdSlZZUDNI/AAAAAAAAH78/Fcq-GAyCBxQ/w1044-h589-no/IMG_2393.JPG

The left side box is now mounted and they both sit at the same angle. I have learned that with all the furniture installed, mounting and dismounting requires some new techniques.
https://lh5.googleusercontent.com/-clXEl3-zSaw/VWdSl8brXGI/AAAAAAAAH8A/pDeTfFPX7Hk/w1044-h589-no/IMG_2394.JPG

Finishing touches minus paint tomorrow.
https://lh5.googleusercontent.com/-I9aePKnO0Mk/VWdSmTUUIwI/AAAAAAAAH8I/U9PelR6nehw/w1044-h589-no/IMG_2396.JPG

[Sir Trev]

Are you going to round over that frontal edge or put a thick piece of edge trim on it? A bad collision from behind means your coccyx may have a guillotine rapidly heading their way. At best it may be uncomfortable on a long ride if you want to stretch to the back of the seat.

[Terry Lee]

Are you going to round over that frontal edge or put a thick piece of edge trim on it? A bad collision from behind means your coccyx may have a guillotine rapidly heading their way. At best it may be uncomfortable on a long ride if you want to stretch to the back of the seat.

Plans are to roll that edge down.

[Terry Lee]

I finally trimmed, drilled and riveted the top box mounting rails. It was good to haul my rivet gun and bucking bars out again and make some noise. The lightning holes will serve double duty for fixing extra items down with bungee cords.
https://lh3.googleusercontent.com/-oNOiJ42jEnI/VWinNEaEt4I/AAAAAAAAH9U/0_10o6Yp3ek/w1044-h589-no/IMG_2397.JPG

The top box has been treated the same as the side boxes. Leftover UHMW plastic has been screwed to the box. I haven't decided whether I'm just going to screw the blocks to the side rails or fashion some sort of locking pin idea.
https://lh4.googleusercontent.com/-79hbQP3v7lU/VWinOM_9sBI/AAAAAAAAH9c/tuU468oqE04/w1044-h588-no/IMG_2398.JPG

This is the one week anniversary of first cutting metal. I thought it would be complete by now. I'm about $35CAD over projected budget. It will come in less than $200CAD all taxes in.

[Terry Lee]

The upper box in now fixed in position. I was going to get all clever and design some kind of easy locking pin mechanism, but ended up just using some SS screws through rail into the UHMW strips. Are Robertson fasteners available in the UK? The side boxes need no retention straps because of their placement. The top box is forward enough to impede the side boxes from moving up. Funny how things work out.
https://lh5.googleusercontent.com/-IKWoGY8wEK8/VWpCrGJRYdI/AAAAAAAAH-0/CZFJA6qXXHE/w1044-h589-no/IMG_2402.JPG

A rear detail view.
https://lh5.googleusercontent.com/-HEsuOy2gmIM/VWpAXyX5C5I/AAAAAAAAH-g/hQUvKZG2ro0/w1043-h591-no/IMG_2400.JPG

The guillotine edge has been rolled down to lessen the chances of have a pound of flesh removed during a rear collision event.
https://lh3.googleusercontent.com/-JrBfOAjng4c/VWpAYvsZNjI/AAAAAAAAH-o/48iQ0XCjktM/w1044-h589-no/IMG_2401.JPG

I've test ridden the new accessorized bike and nothing fell off. I'll put a couple of hundred KM's on to see how things hold up. But before that, everything comes apart for powder coating of the hard bits.

[Terry Lee]

I went looking for a short piece of rubber hose that I could slip over the rear pegs to stabilize the saddle mount and found tennis balls for $1 each. I bought two. With a small slit cut, they fit tightly over the pegs. Plus, it gives a splash of colour to a drab assembly.
https://lh6.googleusercontent.com/-Vj6Q38MqK_Y/VWs1xGEXkSI/AAAAAAAAH_c/X8nKjP2Gcos/w1044-h588-no/IMG_2403.JPG

I had second thoughts about leaving the side pieces unrestrained. After much contemplating, I drilled an undersized hole from inside the box, through the UHMW into the aluminum. A socket head bolt threaded right through and completely immobilized the side boxes.
https://lh3.googleusercontent.com/-0KXsrHdt8uE/VWs1xpt01CI/AAAAAAAAH_k/wYX3EqNsmi8/w1044-h589-no/IMG_2405.JPG

https://lh5.googleusercontent.com/-giBOF1xT1Fo/VWs1yJl90cI/AAAAAAAAH_o/TqIHKIcFIB0/w1044-h589-no/IMG_2406.JPG

Now for some serious testing. From a high of 30C yesterday, to a high of 7.5C today and rain, not today. If you don't like the weather in Canada, wait a minute...

[Terry Lee]

So now I'm out and about with my new cargo hauler. I can get 8 bags of crisps into the rear box. That would be chips to NAmericans. These are a special introductory flavour. Steak flavoured crisps. Wrong on so many levels, yet intriguing. I delivered a bag each to my son and daughter.
https://lh3.googleusercontent.com/6kt9oaiQ_FObKWU_EmKItuCC0SaHC_38B4BLVNNhLCA=w1208-h681-no

I've noticed minor handling changes at speed in windy conditions. At 120 km/h, there's slightly more buffeting in a crosswind. Nothing serious, but detectable.

[Terry Lee]

I finally got around to taking the metal bits in for powder coating this week. I picked them up today and as always, I very pleased. Powder coat covers a million sins. I made some last minute mods to the assembly before coating. I've added some additional tabs to stabilize the boxes. These boxes are somewhat flexible and I didn't want to discover the fatigue cycle. I also cut a hole for access to the rear storage compartment. Space is precious. I have a hatch with a barrel lock that is not yet finished.
https://lh5.googleusercontent.com/-tGnkz-djVQ0/VYSTNdSpG4I/AAAAAAAAi28/CaUvr192F9o/w1044-h587-no/IMG_2441.JPG
https://lh5.googleusercontent.com/-8B-JqI-sTM0/VYSTOg3ZUZI/AAAAAAAAi3E/tPZvnsIxf90/w1044-h589-no/IMG_2442.JPG

One of the additional bracing tabs here.
https://lh5.googleusercontent.com/-tyaHZC8oOxw/VYSTPUTb_oI/AAAAAAAAi3M/YvFgdiOZZpE/w1044-h587-no/IMG_2445.JPG

I was pondering going with white, I'm glad I went with semi-gloss black.
https://lh3.googleusercontent.com/-ayUB75C1-zE/VYSTQvk8ukI/AAAAAAAAi3U/1KG7eLKYhuA/w1044-h589-no/IMG_2443.JPG

I discarded the tennis ball and gave it to a neighbour's dog to play with. 1" rubber hose slips tightly over the rear foot pegs and stabilizes the side pieces. The entire conglomeration rides on rubber dampers and spacers.
https://lh5.googleusercontent.com/-jz4EhcsNt2s/VYSTRkjK3KI/AAAAAAAAi3c/EZm3nJUi_iU/w1044-h589-no/IMG_2446.JPG

And except for the rear hatch cover, it's deemed complete and ready for adventure.
https://lh6.googleusercontent.com/-EBN4D0daNYQ/VYSTTPRYwEI/AAAAAAAAi3k/e-CnSamekOY/w1044-h586-no/IMG_2444.JPG

[keith_d]

Excellent project.

My only concern would be possible fatigue cracking around the lightening hole at the bottom of the big box. You've got a cantilever there, and by drilling holes you've weakened the fulcrum. I'd have preferred holes at either end where the load is lower and a solid portion in the middle where the bending load is highest.

Just my uninformed thoughts,

Keith.

[Terry Lee]

Excellent project.

My only concern would be possible fatigue cracking around the lightening hole at the bottom of the big box. You've got a cantilever there, and by drilling holes you've weakened the fulcrum. I'd have preferred holes at either end where the load is lower and a solid portion in the middle where the bending load is highest.
Keith.

You have a good point. It wouldn't be an ideal design in a high load application. The angle I used was what I had on hand and is hugely over rated for the loads its going to see. An engineer would cringe if they could see some of my TLAR (that looks aboot right) projects.

[Terry Lee]

Just when I thought I was finished. I've been riding with the boxes installed looking for issues. Low and behold, even lightly loaded, there's evidence of the tire/tyre hitting the bottom brace. Sigh... smarter heads on this forum prevailed.
https://lh5.googleusercontent.com/-TQCLDaj3hcs/VYr6bNwQ-gI/AAAAAAAAi4E/cN564nFnwW4/w1044-h587-no/IMG_2449.JPG

I've never been afraid to admit my mistakes. Comes from my aviation background I think. We have a saying, "learn from the mistakes of others, you'll never live long enough to make them all yourself". So with that said, I have a new plan. A .250X1" piece of bar stock is far easier to fit into the angled side panels. Make it undersized and pull back until it snugs up. I will be able to tie in some of the holes from the shelf clips.Plans at the moment are to tie the forward end in with a threaded rod to pull tight against the rear foot pegs and rubber hose installed on them.
https://lh5.googleusercontent.com/-3zJfgV3N4UY/VYr6bvvN9uI/AAAAAAAAi4I/KKw03B8agXI/w1044-h589-no/IMG_2448.JPG


I mentioned that this was a work in progress:)

[Terry Lee]

After squishing the suspension down to the stops with a ratchet strap, I had to move the the bar stock brace even further aft. The tire is now completely unencumbered in its travel. Whew.
https://lh5.googleusercontent.com/-nQjmJo0XUFw/VY8ZhknhJ_I/AAAAAAAAi4o/AYNqXdzf5NA/w1044-h589-no/IMG_2455.JPG

The final touch for this project is a locking hatch for the rear trunk/boot space.
https://lh5.googleusercontent.com/-1E8ES3a8cmU/VY8Zg5SLRVI/AAAAAAAAi4k/3cMRh9VKWcE/w1044-h589-no/IMG_2453.JPG

I'm pleased how the build has worked out. As always, two steps forward, one step back. Thunder Bay, here I come.

[DarrenSV650S]

That looks very professional. Well done :)

[Jayneflakes]

I love that little locking plate, that is ingenious. Reminds me of a little fairy door for the bike. :D

[Geodude]

Looking good Terry, dont forget a wear and tear review after your trip :)

Reminds me of a little fairy door for the bike. :D
That made me girly giggle, cheers JF :D

[Terry Lee]

Looking good Terry, dont forget a wear and tear review after your trip :)


That made me girly giggle, cheers JF :D

I transported home copious quantities of beer yesterday in the carriers. That was a first.

[Terry Lee]

I rode all morning, and now it's Saturday afternoon and I'm bored stiff. I discovered that the hinge pins for the toolbox lids are easy to remove. I had some poly-carbonate in the workshop and some aluminum bar stock.
https://lh6.googleusercontent.com/-nOqfZXPG9JQ/VZgpRCqMQGI/AAAAAAAAi7c/ORTJLLWwtnk/w1044-h588-no/IMG_2474.JPG

Installed a restraining strap...
https://lh5.googleusercontent.com/-K06CwOS7E3o/VZgpSIqKslI/AAAAAAAAi7k/okPO57h-DqE/w1044-h589-no/IMG_2475.JPG

Installed furry baggage...
https://lh5.googleusercontent.com/-Ws-3K7sunWc/VZgpTAaeShI/AAAAAAAAi7s/COBCcmm-Bu4/w1044-h589-no/IMG_2477.JPG

I can't tell if she's impressed, excited or meh!
https://lh3.googleusercontent.com/-rD_ekmJBCIA/VZgpT-XBJbI/AAAAAAAAi7w/3C7Q2CE1Jno/w1044-h589-no/IMG_2478.JPG

I just got back from a short test ride, dog in tow. Working on a short video.

[Terry Lee]

The hound riding with me in her custom wind protected, safety capsule. Strapped in secure and maybe enjoying it. Who can tell?
Y2Gg_YdUrFk

[The Guru]

Bet she loves the wind noise... :-s

[Bibio]

doggy looks well happy in there :-)

[Terry Lee]

doggy looks well happy in there :-)

She lets us know when we displease her by dropping her tail. It never happened. It might be, my wife thinks, she thinks that I'm the Alpha.

[Bibio]

as someone sig on here says ''only bikers know why dogs stick their head out the window of a car''

[Geodude]

as someone sig on here says ''only bikers know why dogs stick their head out the window of a car''
Me :D

Terry ive not seen a dog look so p'eed off before ;) does she always look like that or is it because she's stuck in a tool box :p

https://lh3.googleusercontent.com/-rD_ekmJBCIA/VZgpT-XBJbI/AAAAAAAAi7w/3C7Q2CE1Jno/w1044-h589-no/IMG_2478.JPG

Looks happy in the video though :)

[Terry Lee]

Me :D

Terry ive not seen a dog look so p'eed off before ;) does she always look like that or is it because she's stuck in a tool box :p

That's her "what the h*** is going on here"? I strapped a video cam to her back once with a little harness I made from a detergent bottle. I got the same look. I present the Shih-cam.
https://lh3.googleusercontent.com/-Xb4QOmbzfPg/VZknLPlQF7I/AAAAAAAAi8E/sWhyLqR9OJ8/w600-h338-no/shih-cam.jpg

And life from the perspective of a small furry creature.
WTTbqAPkH0o

[Geodude]

Cool :cool: