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Old 12-14-2010, 11:10 AM   #1
thumpergirl OP
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How to attach Pelican case to rear rack

I have a crf230L with Honda's tubular rear rack on it. I want to install my pelican case as a topcase. With the flat racks it's a no brainer - bolt it on. But I can't come up with a good way to do it with a tubular rack. I was thinking of using U-bolts, but I'm not sure how well that will work.

I am not a welder, nor do I know a good welder, so I'm looking for a solution that does not involve welding.

Anyone done this or have some good ideas?
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Old 12-14-2010, 11:17 AM   #2
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Electrical conduit straps sized to fit the rack with 1/4-20 carriage bolts, heads inside the case so it stays snag-free in there. Nylock nuts so they'll stay put.

Examples here;

http://www.mcmaster.com/#pipe-routing-clamps/=a59lqe
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Old 12-14-2010, 11:57 AM   #3
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awesome. I'm not sure why this didn't occur to me! those are much cleaner than u-bolts. And why the carriage bolts? Just because the heads are tapered? Or is there another reason?

thanks!
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Old 12-14-2010, 02:40 PM   #4
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The carriage bolts have a smooth, rounded head and square lugs underneath. Drill the hole in the case just big enough for the shank of the bolt. When you tighten the nut the first time the square lugs will be drawn into the plastic, which will stop the bolt from turning.

Leaves a nice surface inside the box instead of a hex head or some cut off threads.

Examples here;

http://www.mcmaster.com/#wood-screws...screws/=a5c31c
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Old 12-14-2010, 02:49 PM   #5
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I've always used U-bolts, and just recently did to mount a Givi topcase to my tubular rack on the Scrambler, but you almost always have to dremel part of the shank/threads off as they're usually longer than they need to be. I think the conduit straps will be a lot cleaner.
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Old 12-14-2010, 05:57 PM   #6
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U-bolts or J-hooks (looks like a u-bolt with one leg chopped off).
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Old 12-15-2010, 10:22 AM   #7
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I use a thin piece of aluminum in the case and a thin piece under the rack and then use a carrage bolt (top smooth) and tighen it down from the bottom. The way you spread the load (shock) from a point source to a distrubted load and wond bend the rack or break the box. I try to find a piece of Aluminum that just fits inside the box and another that just fits under the rack. I weighs a pound or two more but I have never had one come off.

I use this approach on my quads as do my buddies. (60lb loads at 35/40 over all sorts of terrain) No failures yet. Other than beating the hell out of the contents inside the Hardigg case.
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Old 12-15-2010, 02:49 PM   #8
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Another option is to use stainless allen head screws. Nice smooth head and no worries about carriage bolts square lug.
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Old 12-15-2010, 06:54 PM   #9
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I have mounted them with the flat part of a U-Bolt
Stainless button cap bolts and nylon lock nuts

Drill on both sides of the bar at a mount point, the flat part of the U-joint goes UNDER the bar.

make sense?


I'll see if I can drum up some pix of mine I had on the KTM
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Old 12-15-2010, 06:59 PM   #10
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dont have any of the Pelican, but similar to how I mounted a tool tube

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Old 12-15-2010, 08:32 PM   #11
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I drilled the Pelican outboard of the tubes and used big Tyraps, going through the box. Worked fine, lasted long time.
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Old 12-19-2010, 05:56 AM   #12
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Don't forget to post pics of the "build".

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Old 12-20-2010, 08:55 AM   #13
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Quote:
Originally Posted by 257bob View Post
Don't forget to post pics of the "build".

Just finished it yesterday. Thanks to everyone for their input!!!! I will post pics soon, although it may be after the new year, but I'll definitely get them up here. It looks great and it's not going anywhere. I got lots of detailed pics.
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Old 12-20-2010, 08:58 AM   #14
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Originally Posted by Truckin_Thumper View Post
dont have any of the Pelican, but similar to how I mounted a tool tube
I want to mount my tool tube to my pelican case now. So you didn't actually use the Ubolt, right? just the metal clamp piece? And that was enough to secure it? Do you have more pics??? (thanks!!!)

I can see the UBolt clamp and washers with screws, but what's keeping the metal strap from sliding? Looks like maybe you used hose clamps and slid them through the little contraption. that's an awesome idea. I'll probably do that too and post pics here.
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thumpergirl screwed with this post 12-20-2010 at 01:42 PM
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Old 12-20-2010, 09:57 PM   #15
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Quote:
Originally Posted by thumpergirl View Post
I want to mount my tool tube to my pelican case now. So you didn't actually use the Ubolt, right? just the metal clamp piece? And that was enough to secure it? Do you have more pics??? (thanks!!!)

I can see the UBolt clamp and washers with screws, but what's keeping the metal strap from sliding? Looks like maybe you used hose clamps and slid them through the little contraption. that's an awesome idea. I'll probably do that too and post pics here.

way off...

I used 4 mount points for the box to the rack

2 "flat bars" per mount point.
two bolts per point

BUT the rear of the box straddled 2 of the rack bars
One bolt on the OUTSIDE of each bar

the front I still used 2 flat bars, and two bolts, but only one of the rack bars.

I sammiched the rack bar with the flat bars and the box on top of the top flat bar

Pelican
Flat bar
rack bar
Flat bar
BOLTS, not the U-bolt

I also used button cap allen head bolts, washers (2 per hole, one inside the pelican and one above the lock nut


so from the inside of the pelican to the bottom (lock nut):
Pelican
washer
Bolt
Flat bar
Rack bar
Flatbar
Washer
Lock nut

does that make sense?
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