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Old 09-17-2008, 10:53 AM   #1
klm4755 OP
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DIY Bungeless strap tiedown system modification on a KLR setup and review

Enclosed is a review of the storage system adopted for my KLR650. The intent was to maximize the bikes carry capacity while providing flexibility, attach point redundancy, and safety. The key to the storage system is the bungee-less attach system. I added plastic 3/4 female buckles to various locations on the bike. The buckles were attached to the bike with 3/4 nylon webbing and sewn in with nylon thread.

sew items

webbing and such

closeup of buckles

durable nylon thread

8x attach female buckles attached to rear rack

additional buckle added near passenger foot pegs

the nylon straps, with adjustable male buckles on each end. 8x total each about 3.5 ft. I also made 2x 3-way splice connectors, 1x single splice connector, and 2x loop connectors. I’ll show sample usage of these items.

here is my daily work bag. I sewn in nylon straps with adjustable male connectors built it. Easy on/easy off with one hand.

1/4 side view

gym bag....same deal, pre-sewn in webbing and male buckles to connect to the bike, no hassles with bungee chords

as attached to bike at 4x points, like work bag

big travel bag, again with pre-sewn straps. Bag measures 22x13hx12w or 3,432 in3

carried a few items for garden, this time the nylon straps were used to restrain the items. Very secure and easy on/ easy off

OK...you say MORE...now to mount this mountain bike on the rack

at 36 lbs 2 oz

al frame from e-bay at ~$180...great deal...with a catch

peddles fold

as does the bike at a frame pivot joint

up and on the rear rack, I did add a pad to the rack to protect it and the bike’s finish system

seems stable, while on center stand, need to strap down while in motion

Thread the straps thru the bike and chinch down tight

here is one of the loop connectors attached to the pannier lid

use this point with a 3 way splice connector

3 way connected with the 3rd body strap lifted

ready to travel....I could lift the tail end of the KLR up if strong enough, by the attached bike

back view

another view....No real difference while in motion, I have not ridden over ~50 mph, unsure of bicycle’s effect at freeway speeds.

keep the bike in a rubber made type storage unit on side yard, out of the way

other bikes stored here

modified the small tool pouch to allow one hand operation. Added a little velcro, capacity = 35 in3

white bed-liner material on the inside cavity, store 2x straps for quick usage, if needed

mounted small shovel on outside of right pannier

mounted small axe on outside of right pannier, notice keyless combo-lock system, open and close with gloved hand...nice

These are the Owyhee style 7.5 width x 14 height x 16 length for a total volume of 1,680 in3 or 27.5 liters or 7.3 gallons each. The intent of the boxes are to provide sufficient secure, waterproof transport storage. I ordered the "no finish" option. added white bedliner and used waterproof bags (don’t really need though as I have never found moisture within the panniers).

added Black bedliner to the bottom of the panniers to protect them when removed and placed on the ground. Protects the finish

nerf bags added to increase storage, protect front end in crash, and offer some wind protection on legs

hand sewn in quick release straps on nerf bags

bag size 14x7.5x4.5 or 475 in3 each

closeup of attach buckle and webbing

sew all straps like so...right side fits rain gear, left side spare inner tube and a few tools

added GPS, radio, watch, volt meter. New corrected speedo dial, bright yellow for visibility

front disc lock, key style...

disc reminder coil attached to male buckle, which attaches to female buckle strapped to hand guard

like so....

registration , insurance, and spare disc lock key in waterproof plastic ziplock

cover one side with black electrical tape, opposite side with velcro

store inside cowling, with velcro, don’t know it’s their unless pointed out

add male buckle to helmet strap and can use the hand guard female buckle to keep helmet secure while getting gas or preping for a ride.

easy on easy off with one hand operation

for secure control, add a chord to the relocated helmet lock

thread thru helmet visor flip

and attach

can position to keep rain out of liner...nice feature
The storage volume capacity in summary:
1. Panniers = 1,680 in3 each
2. Nerf bags = 475 in3 each
3. Big bag (as shown), can rotate sideways for 2 up riding = 3,432 in3
4 small tool cavity in rack = 35 in3
for a total of 7,780 in3 or 33.6 gallons or 127 liters or .13 m3

in comparison this typical carry on style bag has a capacity of 22l x 14w x 10h or 3,080 in3. The carrying capacity of the 4x KLR mounted storage items equates to 2.53x the storage capacity of the travel carry-on luggage.
Keithm
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Old 09-17-2008, 02:19 PM   #2
"D"aily "R"ider 650
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lots of great ideas. i might have to steal some of those.
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Old 09-17-2008, 05:30 PM   #3
klm4755 OP
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Quote:
Originally Posted by "D"aily "R"ider 650
lots of great ideas. i might have to steal some of those.
Getting wacked in the face will force a change into the way you tie stuff to the bike.
Keithm
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Old 09-17-2008, 07:48 PM   #4
Twinsteel
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Where did you get those combo locks for the hard panniers? Me likee.
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Old 09-17-2008, 08:06 PM   #5
ramjet
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Kind of a Swiss army knife of the KLR world. Cool-thanks for sharing.
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Old 09-17-2008, 08:35 PM   #6
klm4755 OP
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Quote:
Originally Posted by Twinsteel
Where did you get those combo locks for the hard panniers? Me likee.
The locks are great, no fumbling around, can set the combo to any numbers, open/close with one hand, good theft deterant, weatherproof (designed for outside gates). Here is the thread on the vendor and step by step install
http://www.advrider.com/forums/showthread.php?t=236118
hope it helps!
Keithm
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Old 09-17-2008, 08:46 PM   #7
plugeye
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is that seat as comfortable as it looks?
shape & size looks right, is it stock under the sheepskin?
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Old 09-18-2008, 09:18 AM   #8
klm4755 OP
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Quote:
Originally Posted by plugeyes
is that seat as comfortable as it looks?
shape & size looks right, is it stock under the sheepskin?
The seat was built by a custom seat builder in Seattle. The sheep skin is draped over it and a small pad, to increase the height abit.
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Old 09-18-2008, 02:08 PM   #9
DirtyDog
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A shovel? Really?

Does this bike see dirt?

Even your bicycle is immaculately clean.

Nice how-to as usual.
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Old 09-18-2008, 04:47 PM   #10
HaChayalBoded
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How strong are those buckles? all the ones I have give way under even the slightest tightening down. also don't you find you lose lots of tensions tying down non compressable hard items? Thats why I like rok straps, a small amount of bungee type cord attached to the bike and lots of plain old nylong webbing used to secure the load so no chance of bungee in the eye syndrome.

I should get myself a small sewing machine....
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Old 09-18-2008, 06:21 PM   #11
klm4755 OP
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Quote:
Originally Posted by HaChayalBoded
How strong are those buckles? all the ones I have give way under even the slightest tightening down. also don't you find you lose lots of tensions tying down non compressable hard items? Thats why I like rok straps, a small amount of bungee type cord attached to the bike and lots of plain old nylong webbing used to secure the load so no chance of bungee in the eye syndrome.

I should get myself a small sewing machine....
I have never had a strap loosen, fail, or break. I did have an issue with carrying ice bag on the rack though. The straps were chinched up, while the ice melt, the strap was less taut. Bungee would have been better in this case.
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Old 09-20-2008, 07:29 PM   #12
klm4755 OP
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Quote:
Originally Posted by DirtyDog
A shovel? Really?

Nice how-to as usual.
You can imagine how many times that shovel has come in handy!
Keithm
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Old 01-02-2015, 06:03 PM   #13
Visigoth
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Great setup. Could you please post details on your axe mount. I'm trying to do the exact same thing with the same gerber axe.
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Old 01-03-2015, 12:01 AM   #14
Tropic-Of-Canada
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Not to knock your idea, but long fiber straps kind of scare me. Buckles are iffy too. how tight can you cinch them down before they bust? If a long one comes undone, it will stop a wheel dead. I still prefer lots of rubber straps for that reason. Even if they are a pain in the butt!

Just my opinion.

Tropic-Of-Canada screwed with this post 01-03-2015 at 12:15 AM
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Old 01-03-2015, 07:51 AM   #15
markk53
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Quote:
Originally Posted by Tropic-Of-Canada View Post
Not to knock your idea, but long fiber straps kind of scare me. Buckles are iffy too. how tight can you cinch them down before they bust? If a long one comes undone, it will stop a wheel dead. I still prefer lots of rubber straps for that reason. Even if they are a pain in the butt!

Just my opinion.

Eclipse among others used to use the fastex style clip buckles to secure their tank, rack, and saddle bags back in the 80s. They can be pulled up plenty tight. the key is that the pull on them must be in a direction to lock the strap. Those who use them know what I mean. It is in the quality of the clip, the strength of the nylon strap, and proper use.
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