Super Tenere 1200: DIY Aluminum Tool Box Mounted to SW Motech Evo Rack

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  • Mock up template for tool box using 1/8" whiteboard, with approx 4.3 litre capacity attached via 5 bolts to SW Motech Evo Quick Detach Pannier Rack.
  • Tire clearance = 1", brake caliper clearance = 1" at max suspension travel.  To ensure these minimum clearances the mounted width of the tool box was limited to 4" exterior dimension because my luggage rack mounts have been custom narrowed approx 1"...the finished width of the tool box rivet to rivet is 3 7/8" + 1/8" anti-vibration rubber spacer between the box & rack.
  • 10 mm longer mounting bolts were used for the 2 upper middle (originals were re-used for the 2 upper outer mounts) & lower back bag mounts...pre-existing re-inforced bag mount holes were utilized.




 

 




  • Material is 0.080" 5052 sheet aluminum + 90 degree 3/4" x 1/8" aluminum angle stock (would use 1/16" angle stock next time & 1 size smaller rivet, or 0.063" material if less weight a priority) attached via JB weld to ease assembly + 3/16" x 1/4" grip aluminum rivets for strength.  This produced a tank  like ultra rigid, but slightly heavy structure @ 3.4 lbs.  The angled stock adds rigidity & provides a stronger mounting point while acting as an internal frame.  Welding would be another option that would make it lighter (although access to the inside front area would be tricky due to the custom shape & narrow access). 
  • Top panel is 1 continuous piece with 2 custom bends for rigidity & water tightness.                               
  • Locking (stainless disc tumbler cam lock w/waterproof rubber cover) access panel at the rear is 7.8" x 4" & will have a locking mechanism + dust/water proof seal.  It consists of an 0.080" plate with 90 degree 1/2" x 1/16" aluminum angle stock bonded & riveted to the inner surface fitting inside the opening to aide torsional rigidity & the outer butting flush to the opening.  A 11/16" x 3/8" rubber u-channel edge seal will provide compression sealing to both the butt & inset part of the cover to aid dust/water proofing & anti-vibration component.  Added a T pull handle to the access panel to assist with removal because of friction with the rubber edge seal.
  • A bottom plate with approx 100 degree bend upward forms a mounting bracket to hold the bottom edge of the door in place.
  • Inside front to back dimension of upper section  = 10.5" (12.5" diagonal), height top to bottom = 9", interior width = 3.6".
  • Tools used were jig saw, metal file, rubber sanding block, vice, drill, rivet tool, acetone, wide masking tape & cutting knife.





 

 






 
 



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