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Old 05-02-2005, 05:53 AM   #1
meat popsicle OP
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Tool Box Idea for the KTM LC4

This idea uses a Stick Electrode Holder (SEH) from almost any welding supply shop. Mine was $11.95 from Clarke Industrial in San Jose, CA. The idea is not mine actually; KTM640Dakar originally posted this idea here:

http://www.advrider.com/forums/showt...1&page=3&pp=15

He sent me a piece of the aluminum to make a carrier (thanks! ) but in my rush to get ready for a big trip I had no time to drill/bend it, so I tried using the stock parts, which are two large clamps for the charcoal cannister:



They work! Note: one of the clamps is the right size and the other is a bit small. The larger one is perfect! - The smaller is not. So I used a longer bolt to allow the smaller one to fit around the tube; it is the one closer to the rear.

I also put a nut between the clamp mount and the clamp on the larger one (in the front) to adjust the "pitch" of the tube, so that it would line up with the offset rear. Seems to work well, although I haven't bottomed out yet...

Here is a shot from the back if that helps to gauge the clearance with the rear tire:


Here is the entire SEH mounted up:


Note (as discussed in the other thread) the length of the tube (18"! ). It may have levered off the frame mounting tabs I suppose, so I took a piece of HD safety wire (I can look at the gauge if anyone wants) and ran it around the frame and thru the SEH's supplied cap lanyard hole

Since you do not open this thing often it doesn't matter, although I might put a quick release clip on at some point. The tube doesn't shake around at all.

The SEH touches the rear quarter panel in my mounting. I thought this better than touching the rear wheel. I rode 700-800 miles last weekend (100 off road) and didn't have a single problem with the setup. For some of that I had soft bags draped over the quarter panels and no problems.


This is what I can fit in mine:


The Ballards tire irons, MTB tire pump (that supposedly goes to 120psi), and the stock tool kit (closest to the front please). The T-handle wrench doesn't fit in the tube (as stated in the other thread) so I simply put it in my fender bag. Problem solved!

Now as I was about to slide the tool kit into the tube I wondered how I would get the bugger out with my big hands. I rememberd the long Motion Pro screwdriver I bought to adjust the idle mix screw and slid the tool pouch in with the angled part of the screwdriver "cupping" it from beneath. Then when I wanna remove the pouch I simply pull on the screwdriver and it hooks the tool pouch! Now I also always have my idle mix screwdriver; not that I need it with the BST

So here it is mounted up. I chose blue to try the best paint scheme that AussieRob is always bellowing about (how's the shoulder mang? ). Looks nice and goes well with the 03 colors. All in all I give the mod


PS - the SEH comes with a rubber cap seal so if it ain't waterproof my name ain't Nathan Arizona!!!
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Old 05-02-2005, 06:12 AM   #2
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Quote:
Originally Posted by meat popsicle


PS - the SEH comes with a rubber cap seal so if it ain't waterproof my name ain't Nathan Arizona!!!
Hey Nathan...what tyre be that?
I just ordered an MT18 and Karoo to try

Nice job too!
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Old 05-02-2005, 06:24 AM   #3
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Originally Posted by Surly
Hey Nathan...what tyre be that?
I just ordered an MT18 and Karoo to try

Nice job too!
Its a Michelin Desert.

MT17 on the front.
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Old 05-02-2005, 07:23 AM   #4
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be careful meat... if that thing decides to take off on you the tire is gonna take a while to burn through it.
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Old 05-02-2005, 07:45 AM   #5
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Don't mean to discourage your attempt but those brackets are just way underbuilt for that. A smaller tube possibly but having it so long like that can play against you.
I confess I played around with the same idea but decided against it after seeing that it could potentially cause some problems.
Just trying to watch out for ya Meat..
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Old 05-02-2005, 08:05 AM   #6
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thanks fellas, that's why I took advantage of the lanyard on the lid so it can't oscillate and crack the welds on the tabs.

maybe I should give it a safety wire around the frame and the tube between the two tabs, just in case... better safe than sorry on this beta testing!
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Old 05-02-2005, 08:10 AM   #7
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Originally Posted by meat popsicle
maybe I should give it a safety wire around the frame and the tube between the two tabs, just in case.
i would doode... speaking from experience... mine had a pretty spiffy stainless steel fabricated bracket that broke... it'll scare the shit outa you if it gets between yer tyre and the mud flap.
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Old 05-02-2005, 08:18 AM   #8
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Quote:
Originally Posted by meat popsicle
thanks fellas, that's why I took advantage of the lanyard on the lid so it can't oscillate and crack the welds on the tabs.

maybe I should give it a safety wire around the frame and the tube between the two tabs, just in case... better safe than sorry on this beta testing!
The safety wire won't do much because it can still move in the tire direction.
What you need are very stable brackets that will not move and if Loaded already went this route than that pretty much answers your question.

Now if you had a pannier bracket, somehow you can tie something in for stability.
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Old 05-02-2005, 08:32 AM   #9
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ah your saying if the tabs break and the tube sways towards the middle axis of the bike and i bottom out I would hit the tube! got to hand it to ya boe, safety is #1!

i suppose i could pop it out thru the side so it couldnt do that; lemme check (not now I am at work). but wouldn't the tire just push the tube back where its supposed to be (and I would likely hear it rubbing)? seems like I would have to be pretty oblivious to miss the warning track...
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Old 05-02-2005, 08:34 AM   #10
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Just

purchase the OEM tool canister, i would assume all have removed the charcoal one by now.
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Old 05-02-2005, 08:43 AM   #11
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purchase the OEM tool canister, i would assume all have removed the charcoal one by now.
if you want to keep the charcoal cannister, you would need to upgrade the routing of the tubing; heard quite a few bikes died mysteriously and wouldnt start until the pinch in the tubing was found. seems like KTM just threw that system in there haphazardly (sp?).
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Old 05-02-2005, 08:45 AM   #12
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here is a shot of a subframe i welded up to strengthen. the tabs for the canister/toolbox were re-enforced quite a bit. an otterbox was installed with stainless steel fabricated bracket to the two 6mm threaded tabs... over a few thousand km they fatigued due to the weight of the factory tool kit in the box and broke off without warning. the box jammed between the rear tire and inner fender, causing the back wheel to lock and stall the bike. damage caused to the silencer, exhaust, inner fender and tyre.

i would not recommend mounting stuff in there if it can be avoided as there is no safe place for things to exit... the only way out is between the tyre and fender!

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Old 05-02-2005, 08:59 AM   #13
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yah loaded, i remember that thread on your upgrade - that is a midpoint shot, you cleaned it up after that right?

well, I dunno fellas, seems crazy of KTM to put tabs there in that way if they are gonna fail (or all too common). I will look into wiring it. if i get some problem i will post my dismay.

thanks for the warnings!

PS - I would like to have the tool box built into the rear quarter panel - but that is a serious aftermarket part or some great DIY work!
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Old 05-02-2005, 09:04 AM   #14
Renazco
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Quote:
Originally Posted by meat popsicle
ah your saying if the tabs break and the tube sways towards the middle axis of the bike and i bottom out I would hit the tube! got to hand it to ya boe, safety is #1!

i suppose i could pop it out thru the side so it couldnt do that; lemme check (not now I am at work). but wouldn't the tire just push the tube back where its supposed to be (and I would likely hear it rubbing)? seems like I would have to be pretty oblivious to miss the warning track...
Anything can happen at any given time especially when your riding off-road.
I've seen the impossible made possible..

Your tire is moving in the momentum of where you don't want the tube to be,
I see a possible catapult or lock up. What if the knobs catch a corner of tube?? You could also drop the bike on that side and bend something, so now you have more problems to deal with. You see where I'm getting at?
A small canister like the stock tool pouch is O.K. and is definetly out of the way but you have a telephone pole back there amigo..

I see an empty luggage rack that can accomodate your tools, tubes and such easily.

Gotta go to work see ya..
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Old 05-02-2005, 09:04 AM   #15
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yah loaded, i remember that thread on your upgrade - that is a midpoint shot, you cleaned it up after that right?
powder coated 'er black to match the rest of the bike... unfortunately i never took pics of the frame itself.

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