terry_g
Ultra Member
I have a nice Kappa 42 litre K-Force top case for my Suzuki DL1000. I wanted to be able to use it on the KLR650 as well so I made an aluminium plate for the KLR rack to install the box. It was a bit of a process.
I went to the local aluminium welding shop and they gave me a piece of 3/16" plate 19" x 16". I set it up in my mill to cut it. A 1/4" end mill and a slow feed rate it took about 10 minutes to make a 19" cut. I shaped it and cut the hole for the tool kit on the mill as well. It is way easier than a jigsaw.
The new and the old.
Shaped and most of the holes drilled and the front retainers installed.
I ordered the mounting kit. The pyramid adaptor would have been a chore to make.
Finished and installed.
A bit of shimming and adjusting and the box fits tight.
I went to the local aluminium welding shop and they gave me a piece of 3/16" plate 19" x 16". I set it up in my mill to cut it. A 1/4" end mill and a slow feed rate it took about 10 minutes to make a 19" cut. I shaped it and cut the hole for the tool kit on the mill as well. It is way easier than a jigsaw.
The new and the old.
Shaped and most of the holes drilled and the front retainers installed.
I ordered the mounting kit. The pyramid adaptor would have been a chore to make.
Finished and installed.
A bit of shimming and adjusting and the box fits tight.