KLR Side Cover Toolbox - Kawasaki KLR 650 Forum
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post #1 of 18 Old 10-02-2012, 06:42 AM Thread Starter
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KLR Side Cover Toolbox

For the past 7 days I have been working on creating an "out-of-the-way" toolbox on my 2012 KLR 650. This is a fiberglass container approximately 1/4" thick that fits inside of my rear left side cover. Was it worth the time, effort and $$$$? Well, I did it as a hobby. Between the fiberglass material, matting, resin, expanding foam, duct tape and some "Cling Wrap" cellophane it cost me less than $50.00.

First I started by taping a layer of "Cling Wrap" underneath the bike's left frame and up around the air intake. I then wrapped the inside of the side cover with the cellophane. I taped the wrap loosely so that the expanding foam would fill all the voids. I also used some cardboard to shape the bottom of the box.





After allowing the foam to expand and harden I then removed the mold and placed it on my work bench for "carving".




Here I have cut a flat surface that will become the back of the box.



Forgot to add...I then laminated the now smooth foam mold with fiberglass material and resin.
After the resin hardened I then carved out the foam and the result was a thin layered mold of fiberglass.



I then began to lay strips of fiberglass mat on the inside to give the shell strength. This was a process that took several days to allow the resin to harden, cure and be allowed to be ground/sanded. In the mean time I installed the "U" bolts that are going to be used to secure the box to the MC frame.



After the resin hardened and the box was sanded down smooth the attachment holes were drilled and the box installed on the bike.



I installed (as a test) a small tool bag with the basic tools that came with the bike plus a few additions. There is still room for more. Sorry..not enough room for a bike-jack.



Here is an underside view with cover on.




I guess that if I want to change the color of the box I will need to do the final resin coat with a pigment.

Last edited by gaucho10; 10-02-2012 at 01:52 PM.
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post #2 of 18 Old 10-02-2012, 07:02 AM
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Quite the interesting project. I'm impressed. People are always looking for nooks and crannies to carry stuff. You should make 'em and sell 'em.



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post #3 of 18 Old 10-02-2012, 07:58 AM
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Originally Posted by planalp View Post
Quite the interesting project. I'm impressed. People are always looking for nooks and crannies to carry stuff. You should make 'em and sell 'em.
Agree! Bet they would sell like hot cakes!
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post #4 of 18 Old 10-02-2012, 09:59 AM Thread Starter
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I don't have a patent yet but anyone here feel free to apply for one.
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post #5 of 18 Old 10-02-2012, 10:30 AM
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Making them and selling works good on paper. The problem is, as a maker of things by hand, you seldom get anything for the labor you put in. People will pay $50 bucks which covers the materials but add in the cost of labor and the stuff sits on the shelf.

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post #6 of 18 Old 10-02-2012, 11:09 AM
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gaucho10 -

I like that!

It's going into the Common Mods and Issues thread.

Wouldn't it be pretty easy to add three or four Dzus fasteners and an ABS cover? How well does the side panel serve as a cover?

T

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post #7 of 18 Old 10-02-2012, 01:40 PM
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That's pretty slick.




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post #8 of 18 Old 10-02-2012, 01:45 PM Thread Starter
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Dzus & ABS covers

Tom Schmitz,

I never thought of using Dzus, as a matter of fact I had to look them up on the NET to see how they would go on. I saw them before but I am presently clueless as to their usefulness. As far as the original stock "side cover", so far it appears to be working fine. I know that once I put more tools (weight) in the box I might have an issue that I will have to deal with...another hobby project

Right now the two top bolts are holding the side cover on to the frame but the bottom "plug" is somewhat iffy. Maybe I can figure out how to install one of those Dzus and will hold the cover on permanently.

The only other things that I want to do to this box in order to consider it complete is to line the inside with something like felt or perhaps some rubber paint to cushion the tools/tool bag. Also, I definitely will have to "LOCTITE" the "U" bolts to keep the box permanent

The Dzus idea sounds good...
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post #9 of 18 Old 10-02-2012, 02:00 PM
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gaucho10 -

What I was envisioning was a Dzus fastener (the female part) molded into each corner and a flat ABS cover with the male fastener in the cover. That would be quite secure.

Though with your fine fiberglass fabrication skills, you might be able to lay up a somewhat domed cover that would fit well within the side panel, affording a bit more room.

I've no experience working in fiberglass, so take my suggestions with an appropriate grain of salt (which might resemble a cow salt lick).

T

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post #10 of 18 Old 10-02-2012, 02:09 PM Thread Starter
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The way I see it is that the side cover appears to be working fine and a second cover "might" not be necessary. Also, by including another cover it will definitely take away some of the space, considering it is somewhat of a small box. I've got to take a look at those Dzus because I might be able to install one right in the center of the side cover at the center plug location.
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