After doing alot of searching the forum, i have found one set of hard saddle bags i realy like. the Pelican 1430's. only problem is, there is no set way to mount these to the KLR 650. DXKLR deserves alot of credit for my mount design, because it is based on his trail tested and true mount, so thank you for taking the time to measure and describe ,in detail, your mount, you have inspired me.
-Use 2 Pelican 1430 Hard Cases.
-Make the boxes easily and quickley removable. (pull a pin, remove the cases)
-overbuild the mount to be strong enough to support the weight of the bike in the event of a spill
-keep weight to a minimum
Step1- tear down the bike,
to the component level, and see whats going on. i have decided to make the mount mount to two places. the OEM turn signal hole, and the OEM luggage rack mounting hole. the mount will bolt to the luggage rack and the frame, through the luggage rack, for impact strength.
Step2- Break out the cardboard,
and start fiddling around for ideas. i use my cardboard as a direct template so when i am happy with the cardboard i move on to the...
Step3- Metal Fabrication
OEM Turn Signal thread size: 10mm 1.25
OEM Cap Screw ( the one on the side of the factory rack that is recessed and holds rack to frame) thread size: 8mm 1.25
The metal is 1/8th" thick x 2" wide Hot roll steel stock
Square Tube: Hot Rolled Mild Steel Square Tube A36, Height 1", Wall 0.065", Inside Height 0.87" , Weight/lineal foot: 0.8264 pounds
Square Stock: Cold Finish Mild Steel Square 1018, Height 0.875", Weight/lineal foot: 2.6001 pounds ( i used about a 3" piece per side)
Slightly sand all edges of the 7/8" square stock to allow it to slide into the 1" square tube. it should have some play, but not too much play (the amount of sanding you will have to do will depend on the metal manufacturer). Champher the weld locations and the end that will be slid into the tube. this makes sliding the stock in slightly easier, and on the other side it will allow a nice strong weld to the 1/8" plate bracket.
Decide on the type of pin/lock you want to use. keep in mind that the pin only has to prevent the tube from sliding off of the stock, it will only be exposed to a small shear force. drill the proper sized hole (slightly larger that the pin/lock shackle). coordinate the drilling of the hole so that it will weaken the stock/tube in its least crutial areas.(toward the box end of the square stock im assuming)
I am welding the solid stock to the bracket that will be bolted to the bike. my theory on this is that i want to keep as much of the weight as close to the center of gravity as possible and to avoid the sagging effect that weight further away from the bracket would have. protect the freshly sanded square stock with a scrap piece of square tube to prevent weld spatter that will hinder smooth sliding in the future. I think its time to invest in a new, better welder, but o-well they dont look prety but they will hold.
The Bike Side of the bracket is Complete.
Step 4: The cases/case brackets
The outside plate is 2"x 1/8" x 6.25"long flatstock
the inside plate is the same flatstock, i just used up whatever i had left. Drill the holes at the same time to ensure alignment.
square the outside plates to the OEM luggage rack
inside plate and 3/8" bolts/washers/lock washers/ nuts (use silicon to seal around the bolts to keep the box water tight, inside and out)