Originally Posted by AdventurePipe
Gadget, did you use the 4 thick lugs on the Pelican cases to put your bolts through? This and using a hard plastic bushing to keep the sharp bolt threads away from the Pelican material would eliminate the problems. And a big fender washer on the inside of the case. Yes there will be a KLR system you can bolt your existing Pelicans onto. And yes I use kitchen trash bags to hold my clothes. I also pack things I need to access often in the right side, and I put the bike on the side stand so the right case is tilted up and nothing falls out. The lanyards help too.
I'm not sure what you mean by thick lugs? pics would help! I"m using the Happy Trail SU racks.. but once your system is ready, I might switch over!