My spin on DUBL-A's spin on the KLR Ammo Can Pannier - Kawasaki KLR 650 Forum
Bike and Rider Gear For discussions on different gear for the ride & rider.

 
LinkBack Thread Tools Display Modes
post #1 of 3 Old 07-01-2012, 10:49 PM Thread Starter
3rd Gear
 
steferf's Avatar
 
Join Date: Jun 2010
Location: Rolla, Mo
Posts: 576
My spin on DUBL-A's spin on the KLR Ammo Can Pannier

The following is inspired by DUBLA-A over here. (click link)

He takes an ammo can and turns it into something like this:





Here is my take thus far (URLs below pictures link to higher resolution pictures so you can see details. I have 20 megabytes of pictues here, so this saves load time):



LOL I just found a tool I was looking for in this picture. lol

http://dl.dropbox.com/u/28110525/klr...ases/Raw/1.jpg
http://dl.dropbox.com/u/28110525/klr...ases/Raw/2.jpg
I think this locking mechanism is gonna look purdy when its all done.



http://dl.dropbox.com/u/28110525/klr...ases/Raw/3.jpg
This is kinda the ugly part of it. The hinge holes were too big for any rivet I could find, so I drilled out new ones. I'll probably fill the hinge holes to look a little better.

Underneath the hinges you see a silver bracket. That was part of the ammo case. I ground the sides of it off to save weight. I wanted to keep that bracket in place to help keep the rigidity below the hinges and provide a little meat to stick the rivets into.

Additionally, if you look closely, you will notice that the hinges are pointed in opposite directions....I screwed that up. I had it right, then second guessed myself at the last second before drilling the holes.

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

See profile visitors post for details and planned mods.
steferf is offline  
Sponsored Links
Advertisement
 
post #2 of 3 Old 07-01-2012, 10:50 PM Thread Starter
3rd Gear
 
steferf's Avatar
 
Join Date: Jun 2010
Location: Rolla, Mo
Posts: 576
It seems the Picture Counting Nazis are out in full force tonight. Thus the Rest of the post.


http://dl.dropbox.com/u/28110525/klr...ases/Raw/4.jpg
http://dl.dropbox.com/u/28110525/klr...ases/Raw/5.jpg
The locking mechanism from the inside. Next picture shows what it latches to.

I mentioned before that I screwed up the direction I put one of the hinges on. This actually makes it so the hinge gets jammed in position when the box is this far open. This is an intentional.

Also, I used spray on adhesive to keep the rubber gasket in place. That did not work (see picture)




http://dl.dropbox.com/u/28110525/klr...ases/Raw/6.jpg
http://dl.dropbox.com/u/28110525/klr...ases/Raw/7.jpg
What my hand is holding in place is a 1 inch by 1 inch aluminum L bracket of 1/16" thick. The lock above will move down and Swivel into place locking the thing. I'm going to take my time mounting that L bracket, because I want it to compress the rubber gasket slightly so it will be waterproof(ish), but not too much as to not bend stuff.


http://dl.dropbox.com/u/28110525/klr...ases/Raw/8.jpg
The hinge as seen from the inside. The hinges are on axis (somewhat) with that loop there.



http://dl.dropbox.com/u/28110525/klr...ases/Raw/9.jpg
The stuff I took off the cases. Approximately 4 lbs of weight savings or 4*2 lbs of weight savings for two. That is about a 20% weight reduction.

I have some more work to do on them, but I think it is coming along quite well. As dubla did, I will spray the exterior with bed liner, and the interior with undercoating. It'll get a rubbery texture on the inside and a tough cover on the outside.

I plan on putting some sort of handle on em. Not sure what type yet. I bought some el-cheapo drawer handles from lowes, but I have questions about their durability. I might get aluminum handles from McMaster for a few bucks.


So the question, is anyone interested in a video tutorial as I make the second one? If you are interested...there is a lot of grinding involved.

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

See profile visitors post for details and planned mods.
steferf is offline  
post #3 of 3 Old 09-26-2012, 05:20 PM
1st Gear
 
Join Date: Sep 2012
Posts: 18
looking good
Bubba681 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










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Ammo Can Pannier Modification Scrapped! Snakeboy66 1987 to 2007 Wrenching & Mods 9 12-01-2013 02:30 PM
Branch meets mirror, mirror starts to spin. Davidnft 2008+ KLR650 Wrenching & Mod Questions 3 02-28-2012 04:45 PM
Ammo Can Pannier Modification Snakeboy66 1987 to 2007 Wrenching & Mods 13 09-03-2011 10:35 PM
Ammo can pannier rack NZWannabe Gadgets & Gizmos 11 07-12-2011 07:10 PM
Ammo Box karl Bike and Rider Gear 2 09-08-2007 10:24 PM

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