Add a Tool Case to Your Pillion Luggage Rack

laconic

New Member
Joined
Mar 9, 2020
Messages
13
Location
North Central NC
While I was messing with getting my seat level the other day I discovered there's an "additional luggage rack" under the pillion seat. It occurred to me that my pillion doesn't pillion any more and maybe I could put that space to use. I had been wanting a way to carry my roadside repair stuff on day trips without dragging the side cases around.

Go to Hazard Fraught and get one of their 2800 size Pelican case knockoffs.

Remove the pillion luggage rack. You'll have to remove the grab rails/bag mounts to get it off so make sure you have your T-50 tamper proof bit handy. Carefully remove the four rubber bumpers from the rack. Bag and tag so you can find them in the future if you need to.

1598122198055.png

Take the rack to the local Ace Hardware or similar and get four grommets to fit the holes. Also get four each panhead style screws 3/4" long, 1" diameter fender washers and nylock nuts. I chose SS.

1598122514485.png

Put the grommets in the holes in the rack. Turn your 2800 case upside down and align the rack. The ribs on the bottom of the case make it pretty easy. Make sure you have the hinges oriented the way you want as well as your front to back setpoint. I biased mine toward the rider because it made it easier to access the rear screws that hold the rack down when putting it back on.

Mark and drill your holes and install your hardware, screw heads inside the box and fender washers and nuts against the grommets on the underside of the rack.

Once you commit (drill the holes), if you plan to remove the decals from the new case, do it before you put everything back together.

Don't over tighten and mash the grommets, you just need to snug things up.

1598123129089.png

I put a little plastic wire shelving cap on the pressure relief valve to keep it from tearing things up.

1598123253553.png

Now put everything back together. I put the bolts for the pillion seat back in their holes so I can find them again someday.

Use blue Locktite and torque the grab rail bolts to 27 lb. ft.

Fits my hand tools, electrical supply kit, Motopump, tire plugging tools, jumper cables, a pair of gloves, extra ROK straps and the owner's manual with room to spare.

1598123697062.png

Top case still fits without interference.

1598123794635.png
 

yoyo

Active Member
Joined
Jan 30, 2016
Messages
681
Location
Swansea UK
That looks really good.

I occasionally take a pillion so need the seat but I did remove the plate under the pillion seat, I cut slots so I can fit and remove it without removing the pillion handles (need to remove the Touratech racks to do that). There's not a huge amount of space under there but I use a PMR and Sena SR10, there's room for that and all the cabling with room to spare.

Sent from my ELE-L29 using Tapatalk
 

Mak10

Well-Known Member
Joined
Aug 20, 2018
Messages
1,351
Location
SE Idaho
The finish on the plastic rack wears and scratches easily. Some kind of protection from vibration is needed. Maybe not if bolted solid.

looks really nice.
 

Jlq1969

Well-Known Member
Joined
May 5, 2018
Messages
572
Location
Argentina
Maybe, for the next time you disarm. It would be more practical to use rivet nuts.
If you want to disassemble quickly, just remove the 4 screws, take out the pelican and put the seat, you do not need to remove the luggage rack to hold the nuts
FDD01C76-1349-4D12-9766-5E6645E8B0C0.jpeg
edit:
 
Last edited:

bimota

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Joined
Dec 10, 2017
Messages
1,541
Location
S Wales UK (Bridgend)
While I was messing with getting my seat level the other day I discovered there's an "additional luggage rack" under the pillion seat. It occurred to me that my pillion doesn't pillion any more and maybe I could put that space to use. I had been wanting a way to carry my roadside repair stuff on day trips without dragging the side cases around.

Go to Hazard Fraught and get one of their 2800 size Pelican case knockoffs.

Remove the pillion luggage rack. You'll have to remove the grab rails/bag mounts to get it off so make sure you have your T-50 tamper proof bit handy. Carefully remove the four rubber bumpers from the rack. Bag and tag so you can find them in the future if you need to.

View attachment 70606

Take the rack to the local Ace Hardware or similar and get four grommets to fit the holes. Also get four each panhead style screws 3/4" long, 1" diameter fender washers and nylock nuts. I chose SS.

View attachment 70607

Put the grommets in the holes in the rack. Turn your 2800 case upside down and align the rack. The ribs on the bottom of the case make it pretty easy. Make sure you have the hinges oriented the way you want as well as your front to back setpoint. I biased mine toward the rider because it made it easier to access the rear screws that hold the rack down when putting it back on.

Mark and drill your holes and install your hardware, screw heads inside the box and fender washers and nuts against the grommets on the underside of the rack.

Once you commit (drill the holes), if you plan to remove the decals from the new case, do it before you put everything back together.

Don't over tighten and mash the grommets, you just need to snug things up.

View attachment 70608

I put a little plastic wire shelving cap on the pressure relief valve to keep it from tearing things up.

View attachment 70609

Now put everything back together. I put the bolts for the pillion seat back in their holes so I can find them again someday.

Use blue Locktite and torque the grab rail bolts to 27 lb. ft.

Fits my hand tools, electrical supply kit, Motopump, tire plugging tools, jumper cables, a pair of gloves, extra ROK straps and the owner's manual with room to spare.

View attachment 70611

Top case still fits without interference.

View attachment 70612
hi,
can i ask for the dimensions of that box please LxWxD looking for one on ebay UK

CHEERS

ROB
 

Don in Lodi

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2012 Site Supporter
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Feb 1, 2011
Messages
5,231
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Lodi Kalifornia
Maybe, for the next time you disarm. It would be more practical to use rivet nuts.
If you want to disassemble quickly, just remove the 4 screws, take out the pelican and put the seat, you do not need to remove the luggage rack to hold the nuts
View attachment 70632
edit:
Do riv-nuts work in plastic? Rubber well nuts might work for a while.
 

Jlq1969

Well-Known Member
Joined
May 5, 2018
Messages
572
Location
Argentina
Works perfectly on plastic. The rivet does not expand in the hole, it contracts in the slotted part, until the nut is trapped. Obviously, if use a washer, will increase the contact surface of the nut .... The question regarding the plastic, comes more on the side of "how many pounds are in that box?, and how much vibration will those holes withstand before cracking?...the nuts with rubber rivet, maybe it is another option. The issue is to prevent the nut from turning when need to remove the screws, which forces you to disassemble the box together with the luggage rack
 

bimota

Well-Known Member
Joined
Dec 10, 2017
Messages
1,541
Location
S Wales UK (Bridgend)
While I was messing with getting my seat level the other day I discovered there's an "additional luggage rack" under the pillion seat. It occurred to me that my pillion doesn't pillion any more and maybe I could put that space to use. I had been wanting a way to carry my roadside repair stuff on day trips without dragging the side cases around.

Go to Hazard Fraught and get one of their 2800 size Pelican case knockoffs.

Remove the pillion luggage rack. You'll have to remove the grab rails/bag mounts to get it off so make sure you have your T-50 tamper proof bit handy. Carefully remove the four rubber bumpers from the rack. Bag and tag so you can find them in the future if you need to.

View attachment 70606

Take the rack to the local Ace Hardware or similar and get four grommets to fit the holes. Also get four each panhead style screws 3/4" long, 1" diameter fender washers and nylock nuts. I chose SS.

View attachment 70607

Put the grommets in the holes in the rack. Turn your 2800 case upside down and align the rack. The ribs on the bottom of the case make it pretty easy. Make sure you have the hinges oriented the way you want as well as your front to back setpoint. I biased mine toward the rider because it made it easier to access the rear screws that hold the rack down when putting it back on.

Mark and drill your holes and install your hardware, screw heads inside the box and fender washers and nuts against the grommets on the underside of the rack.

Once you commit (drill the holes), if you plan to remove the decals from the new case, do it before you put everything back together.

Don't over tighten and mash the grommets, you just need to snug things up.

View attachment 70608

I put a little plastic wire shelving cap on the pressure relief valve to keep it from tearing things up.

View attachment 70609

Now put everything back together. I put the bolts for the pillion seat back in their holes so I can find them again someday.

Use blue Locktite and torque the grab rail bolts to 27 lb. ft.

Fits my hand tools, electrical supply kit, Motopump, tire plugging tools, jumper cables, a pair of gloves, extra ROK straps and the owner's manual with room to spare.

View attachment 70611

Top case still fits without interference.

View attachment 70612
does it lock by using 2 padlocks in those 2 corner edges where the holes are
rob
 

bimota

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Joined
Dec 10, 2017
Messages
1,541
Location
S Wales UK (Bridgend)
i have a touratech rear seat rack that like the rear seat just the 2 bolts to take it off, so i got the box bolted to the rack whitch means to put the rear seat back on its 2 bolts and its off.
IMG_20200927_124645442_HDR.jpg
 

bimota

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Joined
Dec 10, 2017
Messages
1,541
Location
S Wales UK (Bridgend)

schievezot

New Member
Joined
Oct 1, 2020
Messages
16
Location
Belgium
i have a touratech rear seat rack that like the rear seat just the 2 bolts to take it off, so i got the box bolted to the rack whitch means to put the rear seat back on its 2 bolts and its off.
storage.png
what's that case?
Does it fit standard on the side luggage rack?
 
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