My Pelican top box mount - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 18 Old 07-11-2011, 10:21 PM Thread Starter
2nd Gear
 
SD_Charlie's Avatar
 
Join Date: May 2011
Location: San Diego, CA
Posts: 138
My Pelican top box mount

I've been working on this mount for about a week and finally finished it up. A few things I considered prior to designing the mount:

* I didn't want to mount the case directly to the bike.
* I didn't want to permanently modify the bike unless absolutely necessary.
* I wanted to be able to change the position of the case for different types of riding.
* I wanted to be able to rotate the case 180 degrees so I can access the case while sitting on my bike. (to access my DSLR).
* I wanted to be able to make the changes on the fly without having to open the case and remove my stuff.
* I wanted to be able to use the handles on the rear platform when using my center stand or lifting the bike up off the dirt.

Here's how it turned out:

I designed and machined a set of mounts that utilize the same mounting threads on the KLR's platform (4 - M6 screws).


I also machined a set of mounts that are attached to the case and mate to the mounts on the bike. (tongue and groove) There are approximately 13 tapped holes on each mount. (Notice my faithful assistant?)


I designed and produced these SS pieces to stiffen up the bottom of the box where the thru holes were drilled for mounting. The piece on the right also acts as a divider where I'll put some protective foam in to hold my DSLR equipment securely.


Case mounted backwards and forward over the seat. This will bring the weight of the case and it's contents over the seat. I think this will work well when I'm out goofing around on day trips.





Even with the case mounted this far forward, I can still use 4 bolts on each side to secure the mounts to each other. It's very solid.


Centered over the platform.


The mounts are 6061 aluminum. I designed them to lock into each other so there is minimal stress on the bolts as the bike bounces up and down. The total thickness of each mount is .63".

I also did my best to keep the weight down. I think with the case (1550 pelican) and the new parts it comes in around 11 pounds.

I will need to use a hex key to remove the bolts to change position / remove the case. I thought about pins, but I just wasn't comfortable with it.

I haven't had a chance to test it but it sure feels solid, and seems like it will be just as versatile as my KLR.
SD_Charlie is offline  
Sponsored Links
Advertisement
 
post #2 of 18 Old 07-12-2011, 01:18 AM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,615
Garage
SD Charlie -

I wish I could do work like that.

Beautifully done!

T

p.s. BTW - dat dere bike in da back ground - da one wit da blue wheels? Dem forks got put in upside down. Might want to check on dat...

What kine motorsickle dat anyway? Bool?

Tom [email protected]

The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 07-12-2011 at 01:27 AM.
Tom Schmitz is offline  
post #3 of 18 Old 07-12-2011, 08:43 PM
Neutral
 
Join Date: Jul 2011
Location: almost SE PA
Posts: 4
nice job, and it looks like the inspector in pic 2 approves
tunp is offline  
 
post #4 of 18 Old 07-12-2011, 10:33 PM
1st Gear
 
Join Date: May 2011
Location: San Diego County
Posts: 84
Chuck, nice work! You may end up with requests to distribute. Are you up for a ride this weekend?

07 Black/Silver

Carpe Diem
Sandiegowheels is offline  
post #5 of 18 Old 07-12-2011, 11:51 PM
1st Gear
 
Davidnft's Avatar
 
Join Date: Jul 2011
Location: Northern KY
Posts: 68
Sweet setup.

What do you charge for those brackets? I would love something like that but could not come close to building it as good as that.
Davidnft is offline  
post #6 of 18 Old 07-13-2011, 12:14 AM Thread Starter
2nd Gear
 
SD_Charlie's Avatar
 
Join Date: May 2011
Location: San Diego, CA
Posts: 138
Thanks for the kind words fellas.

Quote:
Originally Posted by Tom Schmitz View Post
What kine motorsickle dat anyway? Bool?
Yeah, that's my Buell 1125r (2008). She'll probably go up for sale soon.

Quote:
Originally Posted by Sandiegowheels View Post
Chuck, nice work! You may end up with requests to distribute. Are you up for a ride this weekend?
Sounds good, let me know.

Quote:
Originally Posted by Davidnft View Post
What do you charge for those brackets? I would love something like that but could not come close to building it as good as that.
I haven't given it much thought. I have yet to put them through their paces. Let me get back with you on it.
SD_Charlie is offline  
post #7 of 18 Old 07-13-2011, 12:22 AM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,615
Garage
Quote:
Originally Posted by SD_Charlie View Post
..Yeah, that's my Buell 1125r (2008). She'll probably go up for sale soon...
Not sell Bool. Dat cool bike. Fast. Even if fork not right.

T

Tom [email protected]

The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
Tom Schmitz is offline  
post #8 of 18 Old 07-13-2011, 01:35 AM
Threadjacker
 
Lockjaw's Avatar
 
Join Date: Jul 2008
Location: Benicia, CA
Posts: 6,750
Nice job, man! Don't sell the Buell, they are gonna go up in value for sure.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
Lockjaw is offline  
post #9 of 18 Old 07-13-2011, 06:39 AM
1st Gear
 
ruralgold's Avatar
 
Join Date: Jul 2011
Location: Front Royal, VA
Posts: 19
Sweet setup on that case and brackets. One of these days I'll get around to trying stuff like that(not). Awesome.
ruralgold is offline  
post #10 of 18 Old 07-13-2011, 11:42 AM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,344
Very, very nice work. I'm impressed. You put a lot of thought into features and how you needed to use the case and made it happen.



planalp is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in













Similar Threads
Thread Thread Starter Forum Replies Last Post
Pelican 1550 as a top box Waynem Bike and Rider Gear 4 12-01-2011 05:18 PM
Pelican Cases Light Train 2008+ KLR650 Wrenching & Mod Questions 7 06-08-2011 11:30 AM
ColoradoTom's Pelican hard case mount ColoradoTom How To's & Tech Guides 25 03-23-2011 07:55 AM
Looking for a trunk mount for pelican case??? dad KLR & Other Motorcycle Related Discussion 2 07-07-2009 04:54 AM
Which Pelican case would you get? Goose 1987 to 2007 Wrenching & Mods 7 07-15-2007 09:55 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome