Diamond Plate Toolbox Saddlebags

[TopCatGr58]

Well,
I decided to post in a new thread, didn't see much discussion in the Yamaha Hard Bags thread with regards to my project. I got the 2 boxes cut down from 24" long to 18" long....just right! And then of course I see some diamond plate toolboxes in the Northern Tool catalog that were only 20" long....possibly could have made those work, but oh well.

Got the hinges moved to the leading edge, got the slimline locking latches secured, handles affixed, and remaining holes plugged! The only weigh about 5 lbs each being aluminum!!

I started working on the hanging hardware using a variety of pieces of 1/8" thick angle and plate weld steel. It's amazing how long it take just to prepare it, grinding all of the protective coating off all surfaces to make welding cleaner. They will sit just behind the shocks and stop at the end of the rear fender.

Even though I have used expensive diamond plate boxes($50.00 ea), the same could be done with much less expensive steel toolboxes($10.00-$20.00), and there are ones much closer to the desired 18" length, so no cutting and shortening required, and could be easily painted to match desired color schemes!
T.C.

[trukleon]

pics

Even rough art in progress deserves some pics,,,,C'mon,, don't be shy!!!

[btdtdan]

I think TC may be afraid he will open Pandora's box and have to start taking orders?????

[trukleon]

point

Methinks you have a POINT!!

[TopCatGr58]

A few pix

I hadn't had time to upload them to my web space when I posted my earlier message, so now that I've got them there, HERE THEY ARE! First showing the Full Around recessed sealing lip, and the 2 separate hinges vs. a piano hinge.

The jig saw worked well to make short work of cutting it up!

This shows the length of the original box,and the shortened one.

Closeup of welds, aluminum is a b*tch to weld!

Here it is with handle, hinges and lock latch complete.

Just showing relocated hinges.

And slimline lock latch

[btdtdan]

T.C,
Way past cool. Hold out your hand so I can give you a high five for a good job. How wide are these boxes. Will the trunk be large enough for a helmet? Ya done good.
Dan

[jazzrat2000]

very cool!

[Wayne]

Gee TC, you gona make your XS look like one of those cool African tourer bikes.

Now all you need to do is build a bigger gas tank with that boiler-plate and you will have a bulletproof XS.

[TopCatGr58]

The boxes are 10" wide, 9" tall. There won't be a trunk, though. I don't do that kind of long distance touring,
(have trailer- will tow) just wanted some more durable ones vs. the fiberglass/ABS style, and didn't want to pay $$$ for fancy suitcase removable styled ones!

I am planning on an XJ tank conversion, so I will have a little bit more capacity. As for strength, the diamond plate isn't really that strong as aluminum. If I had gotten some steel diamond plate it would have been, but it would have been much heavier. The steel framework mountings will be heavy enough. I'm making them from 1/8" thick combination of 1-1/2 and 1" angle iron, along with some 4" flat plate sections.

I'll be posting more photos of the mounting frame once I get done fitting, cutting, and welding it together. Now I understand why it takes OCC so long on their fabrication projects!
T.C.

[btdtdan]

I think you should start figuring a price for those that are gonna say...make me some.
Dan

[nashville_bill]

Looks great T.C.. I'm thinking about making some "Paniers" for my V-Strom.

[TopCatGr58]

More Photos

Hey folks,

Update, got the mounting slots cut into the brackets, and the carriage bolts on the boxes. I'm still working on the backrest with sliding adjustability so that I can use it, or my pillion. The brackets stick out further behind the boxes on purpose, that is where I'm going to mount the turn signals to!!

The thin flat plate got weaker after cutting those keyhole slots, so I'll be welding some reinforcing strips along the wheel side. I'll also be welding some 1" square tubing near the back to hold the back rest 3/4" square tubing, with cleavis type pins latches to set it in place where needed. Okay, here are a few shots!


Note the GODZILLA name on the side of the box, it's spelled with those 2" tall reflective mailbox/house numbers/letters, to add more visibility from the side!!

[jazzrat2000]

those are excellent!

[btdtdan]

I second the motion. Good work T.C.

[TopCatGr58]

More progress and photos

Hey there folks,

Just wanted to show essentially the finished product, complete with adjustable backrest and turn signals mounted! Now after you look closely at the pictures you may wonder how I can get the bags open with the lock latch right behind the turn signal stalk? WELL, I can't exactly!! I thought I had enough clearance, and didn't realize the heads of the signals were going to end up right in front of the latches! DOH!

SO....I just think of it as another security measure. I CAN get them open by unlocking the sliding pin Door Lock on the inside edge of the mounting brackets, which will allow me to lift the entire bag up a bit to clear the latches! Then after accessing the bags and closing the latches, I then set them back down in the brackets and push in the pin lock!!

Perhaps later I'll get some other slightly shorter length signal stalks...I had a fun time cutting the square hole in the mounting frame so I don't want to do that again!

They're almost straight/level with the side profile, and plenty of clearance with the pipes!