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Well, I received my DS tool box yesterday, and am actually quite impressed with the construction and materials of the box itself. I was a bit dismayed to find some scratches in some areas all over the box... One particularly bad one clean across the door plate, and a another bad set up near the front mount where apparently the little bag of parts rattled around and allowed one of the stainless steel brackets to carve up the surface finish pretty good. Neither is really that big a deal to me as I'm always more concerned with function over form and I ride my bikes. I don't sit at home polishing them, looking for blemishes. I just thought I would pass it along so Jason could perhaps pass the info along to DS in Spain and they could perhaps pack the parts a bit better for future shipments.
I do have to say I have some genuine concern about the mounting brackets, especially over the long term. They are made from some nice, stout stainless steel, but the way the brackets were cut and bent sure look like they are a crack waiting to happen...
Take a look at these pics to see what I mean.
The entire weight of the box, and whatever contents one puts in it, have to be carried by these brackets, and though the the material itself is more than strong enough for the task where those cuts are made, and how close they come to the bolt slots, is just asking for a stress crack from the cut to the slot. It's not hard to see how once that happens that the whole box will then be hanging from a much thinner bit of material on the other side of the bolt slot, and I doubt that remaining section will be able to stand the load and vibration for very long.
I'm still pondering a really good solution for these brackets here that came the box... My first thought is simply a nice weld to fill in that cut will help immensely. Perhaps even weld in a gusset that had a tongue that fit into the slot and provided a triangular brace between the box mounting flat and the upright section that attaches to the bike. My only problem with getting the welding done is not knowing specifically what kind of stainless steel these brackets are. Anyway, until I figure something out to do with these brackets I don't think I'm gonna' mount the box up just yet.
On another note, if any of you guys here in the USA are planning to have some spare keys made know that you *might* run into a problem unless you check with a real key & lock shop. Whenever I get an accessory like this that has locks I always immediately go and get a couple of key copies cut, just in case. Fortunately one the best (and biggest) key & lock shops in the area is right down the street from me and I do a lot of business with 'em. Over the years I have not ever been able to totally stump them with weird keys from different parts of the world, but the keys to this DS Toolbox almost did...
In the end one of the great, experienced guys there, Kevin, found an ancient, old Yale key blank that had the same groove layout, but to first look it the blade of the key would be too short. He was able to cut the top and bottom of the blade back toward the fob so it matched the length of the original key, and *POOF*, he got the job done!
I'll try to get some pics of the new keys and the scratches later.
This all just FYI, Jason... But I sure would check with DS in Spain about those brackets. Maybe they can make a change in their design and production to avoid such a deep cut that leaves so little material between it and the bolt slot.
Thanks!
Dallara
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