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.