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Old 07-24-2007, 03:10 PM   #1
Stretch67 OP
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FrankenJesses: The Mad Scientist Strikes Again!

Jesse aluminum boxes have always been my preferred luggage system, but with the popularity of BMW's GS, Jesse has stopped production of all their other bags and focused entirely on aluminum boxes for BMW's. The man knows what side his bread is buttered on.

But those of us who ride bikes other than GS's (and want Jesse bags) are in a bit of a pickle.

That is, those of you who are not Mad Scientists.

I picked up a used set of Jesse's from our own SBryan on ADVrider's "The Flea Market". His had been on a BMW R1150GS and were in great shape. The only trouble is, BMW's exhaust is on the left side, while a Tiger's exhaust is on the right. Not a problem for The Mad Scientist.

So, what do you do with a several-hundred dollar set of bags that don't fit your bike? Cut 'em up.



Like my radius template?


Removing the backs of both boxes...


And now to swap the backs (right back onto left box, and vice-versa)


Maybe I'm getting in over my head. I ought to send these things back. Think SBryan will notice?


Welding completed, now lots of grinding and sanding to make everything cherry...


Cutting the unneeded portions from the BMW mounts...


And creating from it, a custom Tiger mount...


The Triumph plastic bag mount...


And the portion of it I used as a base for my custom mount pictured above...


A bit of bodywork, sanding, and paint (DuPont Imron polyurethane in the original Jesse color) on the boxes, and...

Ta-daaa!


Front mount...


And the rear...
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Stretch67 screwed with this post 07-24-2007 at 03:45 PM
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Old 07-24-2007, 03:26 PM   #2
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Son of a bitch

Man, you're really something. Don't know what, but you're something

Umm, do you by any chance still have the top part of those mounts? You know, the part with the lock?
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Old 07-24-2007, 03:28 PM   #3
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WOW, that's a lot of work for a pair of bags...

I like the way you think!

I had the Jesse bags on my Tiger before they stoped production. The mounting design was not the best. The bags had no cross support and bended inwards. Especially the exhust side. It was far in, the bag would bump up against rear brake caliper assembly on big bumps.

Looks like you solved that problem by puttin in a cross brace in the back. Nice work.
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Old 07-24-2007, 03:33 PM   #4
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Is welding aluminum as much of a PITA as everyone seems to say it is?
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Old 07-24-2007, 03:36 PM   #5
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Quote:
Originally Posted by Cos
Son of a bitch

Man, you're really something. Don't know what, but you're something

Umm, do you by any chance still have the top part of those mounts? You know, the part with the lock?
I do, but I'm trying to keep all the parts together. This winter I'm going to go back and build a stronger set of bases (the parts that actually bolt to the subframe and hold the mounts), and substitute them for the Triumph items I'm using for now.

Then the whole set of Triumph bags, mounts, and hardware is going on FleaBay to help finance this little venture.
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Old 07-24-2007, 03:39 PM   #6
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Quote:
Originally Posted by jagec
Is welding aluminum as much of a PITA as everyone seems to say it is?
I have a Craftsman (made by Century, I think) 85-amp MIG welder with the gas system and aluminum kit. I was using Helium gas and .030" 3034 aluminum wire. It takes a bit of practice, but I was getting pretty good penetration and passable-looking beads.
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Old 07-24-2007, 03:51 PM   #7
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Quote:
Originally Posted by Stretch67
I do, but I'm trying to keep all the parts together. This winter I'm going to go back and build a stronger set of bases (the parts that actually bolt to the subframe and hold the mounts), and substitute them for the Triumph items I'm using for now.

Then the whole set of Triumph bags, mounts, and hardware is going on FleaBay to help finance this little venture.
Crap
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Old 07-24-2007, 04:12 PM   #8
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Sorry.
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Old 07-24-2007, 04:59 PM   #9
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I come to this site quite often, but rarely post. I just have to weigh in here and say-- damn impressive job!

I w
ish that I had skills like that.

fish
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Old 07-24-2007, 09:40 PM   #10
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A little late for this comment, but... Could you have switched the left and right sides, then deal with lids that open the wrong way?



Sorry for the simple, smart assed remark in response to a truly impressive piece of work, but it was the first thing that I thought of.

Nice Job!
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Old 07-24-2007, 09:48 PM   #11
Stretch67 OP
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There is a left bag and a right bag...

See how there is a portion cut out of the lower front, to make room for your feet when pushing the bike (as in sand), and for more room for the passenger's feet.

Simply swapping the bags would have eliminated this handy feature and my big-assed feet would hate me for it.

Besides, anyone who knows how Jesses are supposed to be mounted would catch on immediately.

"You put the bags on wrong to fit your bike, didn't ya?"
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Old 07-24-2007, 10:21 PM   #12
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Ya done good
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Old 07-24-2007, 11:17 PM   #13
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Quote:
Originally Posted by Cos
Son of a bitch
+1

Very. Sharp.
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Old 07-25-2007, 03:27 AM   #14
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nice job! Looks sano...but would have liked to have seen the final grind down shots too!

Well done man!
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Old 07-25-2007, 06:33 AM   #15
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Very nice job Stretch. One question, was there a reason you didn't reuse the Tiger quick disconnect mounts? I've thought about buying some metal cases and transferring the mounting hardware off the Tiger bags to retain the ability to quick detach. But I've not looked close enough at the hardware to see if this approach would be feasible. Alas, I have no welder or welding experience but know if I drop with the Tiger cases they're dead meat. That's why I offroad with only the Topcase mounted.
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