Well, I'm all for recycling. Especially when it means I get free stuff to bolt to my KLR.

The same interesting customer that the Storm case was originally destined for also takes a small bag from us, for keeping cables in. Unfortunately one of these bags had a broken zipper tag/handle. Save throwing it out, I thought it might make a good tool holder for the front mudguard.

So, here's the case (cable tie now in place of zipper tag, so I can open and close it)

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3014.jpg

Cut some aluminium plate to fit in to the bottom of the bag. This'll keep the bag strong and stop the fixing bolts pulling through. Drilled it and bolted it to the mudguard with some stainless nuts and bolts.

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3015.jpg

I think it looks pretty good. In there's a couple of screwdrivers, a 1/4" drive with a range of sockets, an allen key set, some self-amalgamating tape, a pair of pliers, a pair of side cutters, some cable ties and a full size hacksaw blade.

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3017.jpg

I also replaced all the rubbish OE panel retaining screws. They appear to be made of a mixture of fairy-dust and plasticine, so I've swapped them out for some nice allen head stainless jobs with large washers.

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3009.jpg

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3012.jpg

On the rear panels, I swapped the retaining screws for some eye bolts. This'll give me more options when I need to lash things down. I used some expanding rawlbolts and just removed the outers. They were about £3.50 for a pack of 10, so I didn't mind taking them apart!

On the left is the OE screw, then the bolt (with a couple of nuts locking it off at the right depth) and then what the bolt originally looked like.

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3005.jpg

And this is it in situ

http://i726.photobucket.com/albums/ww261/trailer-guy/KLRSB3007.jpg

This is a great idea.

Nice work!

Back in my Moto courier days we used to swap all the screws on everything with Allen bolts so the only tools you needed to carry were a 6 8 10 12 Allen wrenches and a adjustable wrench for the nuts. Even all the engine cases and what not can be changed. Seems I remember something about bike specific replacement kits for this purpose.

Made life simple light and easy.

Clever, clever UK guy....
I'd already swapped out the standard bolts for sidepanels and
seat with Allen head bolts, but that idea of the eyebolts is genius.
Now you can insert/tighten bolts with your fingers...

Clever clever....

Mac

Very nice. I might round the edges of the aluminum insert or put a little tape on them. They look just right for shredding nylon. Good stuff. I'm slowly replacing bolts as they fall off. ;)

Always like to see good, practical and original ideas for the KLR that come from a hardware store or kind of out of nowhere, like the stuff you got from work or stuff folks just happen to stumble upon. All your recent additions/modifications are great, practical ideas. Nice work!

Thanks guys, you're all very generous with your comments.

I can report, having just done a 300 mile weekend trip in to the 'west country' with some very good friends, that everything seemed to work as planned / hoped / expected!

I was pleased for the tool bag to be there - I had an overheating moment, so had to strip the mule down a bit and also a snapped speedo cable that I had to replace, so the tools were used. They were also used to refit a side panel on a friends' Buell!

The eyebolts worked well, too and were pleasingly sturdy. Thanks Mac - that's exactly right, I finger screw them in and then put a screwdriver or allen key through the eye and give it that extra tweak to make sure it's tight.

I'll check on that Lockjaw, thanks for the heads-up.

Thanks guys, you're all very generous with your comments.

I can report, having just done a 300 mile weekend trip in to the 'west country' with some very good friends, that everything seemed to work as planned / hoped / expected!

I was pleased for the tool bag to be there - I had an overheating moment, so had to strip the mule down a bit and also a snapped speedo cable that I had to replace, so the tools were used. They were also used to refit a side panel on a friends' Buell!

The eyebolts worked well, too and were pleasingly sturdy. Thanks Mac - that's exactly right, I finger screw them in and then put a screwdriver or allen key through the eye and give it that extra tweak to make sure it's tight.

I'll check on that Lockjaw, thanks for the heads-up.

No problem. Possibly over-thinking things, but that's a neat bag, hate to see it shredded. :)

Here's the eye bolts in use. The eyes are big enough to accomodate a ratchet strap hook and, as long as you don't give it too much 'phys', then they seem to hold up ok.

http://i726.photobucket.com/albums/ww261/trailer-guy/AsheFarm2011001.jpg

uk trailer guy -

I see, now, why you call it the mule.

BTW, excellent use of pink.

T