Ammo can cases and trunk/box

Hey all,

I've had many requests for pix of my DIY boxes an trunk. I'm in the process of getting the bike ready for 2000 mile, 3 week ride across South Dakota, Wyoming and Montana.

I think the whole set up cost me about $60.

I used 20 MM ammo cans that can be found for less than $20 each at your local Army Surplus shop. I got mine for about $14. The box on the is a Rubbermaid box that found in Walmarts hardware section and I think it cost about $18. Other than that there are about 10 1 1/4 U-bolts and a bit of steel bars.

I also just installed a set of adjustable handlebars; thanks to zwaterer. I have yet to paint them but they are awsome. Much more comfortable fro my riding style. I also attached a "dashboard" to them for my GPS and Catterbox communication setup. The cross peice is an old part from a camera tripod and the aluminum plate is part of the deck of a razor scooter, really. I hate to spend money if I can recycle and apply a little creativity.

Heres some pix.

Hope this inspires you

The Buff

 

That's the same trunk thing I used on my old 850 Suzuki and it worked great. It's even water proof in a downpour (just ask me)
I would suggest changing those wing-nuts for acorn-nuts inside those side boxes. It would make them a little more user friendly and probably save your knuckles when reaching inside them.
It looks like your ready for an adventure!!!

 

You may also want to consider just going with lock nuts. With my side bags, the vibration tends to loosen things up very quickly.

Good idea with the ammo crates as they come already waterproof.

Have fun on your adventure!

 

I was eyeing some ammo cans at a surplus shop a while ago.... smaller ones, but still similar idea....

I love those handle bars.....

 

Those are the same (I think) bars I have on my XJ1100.
Anyone want to trade me for some conventional clamps so I can use motocross bars?

 

TECHLINETOM I have a set of 650 maxim clamps I'ld be willing to trade if they will work,let me know if interested and we'll see what we can work out

 

I had concidered and tried several different ways of attaching them and found this to the bestfor several reasons.

I want to be able to remove them fairly quickly and easily if needed, especially on the right side as it hinders access to the seat latch.

All I need is a pair of pliers to remove in just a few minutes.

The ubolts were put on the bike and tightened down in place so they stay where they are. When not holding the cases to the bike I cap them with acorn nuts. There is a lock washer behind the wingnuts wich seems to hold pretty well. I put on about 240 miles the other day and found no loosening of nuts.

Yes, you do have to be careful when packing the cases as well a unpacking. I put everything in stuff bags which helps to eliminate cathing jackets or other clothing when pulled out.

I'm sure that in the next couple of weeks this system my see a few more tweeks. I am in the process of planning a 1500 mile camping ride through some of the most desolate country in the US. I'll keep you posted of any changes made in the meantime.

The first change will come this week when I repaint the cases with silver HammerRite paint. The idea to repaint came from someone here and may make it look alittle more like the BMW I lust after.

Now that I've put these new bars on I have tripletree crown clamp available if anyone need it.

The stock bars are headed to another fella on the site to help him get his bike on the road. This community is a beautiful thing.

What goes around comes around, even the good stuff.

Keep the suggestions coming.

The Buff

 

Well I won't doubt you have thought it through. Nice work, give us an updated picture with the paint if you have a chance.

Stephen.

 

sorry for the double post.

 

Hello Great_Buffalo. I have been very intrigued with your ammo boxes. I know that I have read the answer for this but can't fine it now. How much did your's weigh empty? And when then were full did it affect the handling? I am in London, Ontario and have not been able to find any yet, but I keep trying. My bike is a '83 750 maxim and I would like to try what you did. Thanks

 

Try Princess Auto. They regularly have them available for a decent price. Don't think I've ever seen any as big as those 20mm cases though...

 

Might want to try Novacks downtown as well?

 

Double post handled. I love the cans. Could you get a clearer picture of the mounting frame/points?

 

Thanks for the nice comments.
I have spent many miles on adventure rides and the cases work great: water/dust proof.

I think they are 7-8 lbs each and when they are loaded the bike does very well. The only thing I need to address is to put air shocks on the back to keep from botoming out my suspension.
have painted them silver and have added a inexpensive trunk I bought from JCW.

I will try to take a few more pics for details

I usually have access to these cans so if anyone is interested I may be able to set you up with cases at cost plus shipping, I think they are about 18 bucks apiece.

I think my next project will be to install Marmite cans instead. They ere a little bigger and a different cover.

The Buff

 

Great_Buffalo,
My compliments to you on your bike. It definetly gets the job done, even if it's not meant to be a show bike. I myself have used that same setup on an 850 Suzuki at one time in the past and it worked out better than expected.
I used a piano hinge (lfull length,one peice) on the plastic Walmart storage box, to make it more convenient to open and close.
The ammo box saddlebags would do you well if you reversed the bolts (nut go on the bike side of the boxes) and used carraige head bolts (smooth rounded heads) so it would be smooth on the inside of the boxes.
I've scraped enough knuckles to know it's worth your time do it. Your shocks can just be swapped for ones from a larger, heavier bike so they won't bottom out. As long as the mounting holes are similar to yours and the length is the same, you should be good to go.
Have a great time on the trip and be safe!

 

I have a picture to better show how I attached the cans. PainterD has some good points on the mounting arrangement but considering I want to be able to remove them, on the side of the road for instance, I wanted it to be quick and easy. I can have them both off in less than 3 minutes with only pliers.

The mounting is done with only 3 U-bolts each side as well as a speader on the rear to keep them from sagging inward at the bottom. This was made from a piece that came with my fairing that I didn't need for my bike. I beleive strongly in recycling, cause it saves me cash. It took 2 tries to get the mounting spots right, thats the reason for the extra holes in the can. I put bungy attachment points on the top of the cases that have come in handy for those camping trips

I have also replaced the Rubbermaid box on the back to a JCW cheap trunk that I think I got for 30 bucks plus shipping.

Here are the pics:

 

Planehue,
I just reread your post, so, to adress the handling. I have had this thing loaded down with my lard butt at 212 lbs and another 100 - 140 lbs of gear nessecary for 2 weeks on the road. I travel the road less used most of the time and much of that dirt or worse. In those conditions I've had not handling problems. I think the fairing on the front helps to equalize the weight. Ihave also had no trouble on the super slab with handling.

The only problem as PainterD made reference to is the shocks. It does bottom out at times.....no all the time. If I continue to run this bike in it's current set up I will install some air shocks to take care of that issue. I've just learned to slow down in bumpy conditions.

I'm trying to live the BMW GS lifestyle on a XJ budget. Things are changing thought. I have a BMW R100 GS project that I hope to have buttoned up by fall, its a slow process. I buy parts when I have extra cash.
There is a Buell Ulysses in the shed as well. But my oh my how I love my XJ, I wish I could find a way to make it more comfortable. I've spent many many hour shaping seats but have yet to hit on the secret.

The Buff

 

Buff,

Earz_cd pointed me to this site www.Diymotorcycleseat.com it looks like it could be helpful.

mikeg

 

I've looked there in the past but haven't visited lately. They stopped selling foam and gell pads. They had them for great prices at one time but when I was ready to buy they no longer carried that stuff. I'll have to go back and rethink the process.
Thanks

The Buff