New Happy Trails cases with inside mounted Rotopax

Mitch580

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Jul 1, 2019
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#1
I'm sure this isn't anything new but I'm happy with how it turned out. It's a 3.8L (1 gallon I think?) Rotopax, it took a few attempts and a bit of head scratching but now it's tucked away in an otherwise useless space. You have to have the bike on the center stand to get it on and off but that's fine since I don't expect to pull it out except a couple times a year to rotate the fuel in it. I've got 42 000 KM on the T and I've never had issues with fuel range but I usually carry a little can just for peace of mind so this makes my pack a bit simpler.

Also, FWIW the happy trails cases are great. Great build quality and while they lack some features like a quick release I appreciate that the simple design makes them tough and reliable. The mounting points on top of the lids is genius too. 20190817_164901.jpg 20190817_164906.jpg 20190817_164915.jpg
 

gv550

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#2
Good work! I did the same with OEM panniers. image.jpeg
How much clearance do you have to the brake caliper? I learned by experience that you need at least 3/8 inch cold, because the fuel can expands with heat and agitation. I also learned that if I attached the Rotopax when it was expanded with warm fuel that it becomes very loose the next cool morning. Mine actually fell off the mount but remained trapped by the frame.
Welcome..... and where are you in Ontario?
 

Mitch580

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#3
I went and checked again because your question made me paranoid haha but it looks like I have a full 1/2" to the brake line as it sits right now at 20 Celsius so I think I'm ok there.

If anything I'm actually more concerned about the swing arm, I only have about 3/16" clearance to the swing arm but I can't tell if it would be conflicting even if the suspension is bottomed out, kind of a tough thing to test. Best I can tell, even if the can was swollen by the 3/8" and the swing arm did come up far enough to connect, the tapered top of the swing arm would easily push the can over the 3/16" necessary. It's hard to see in the pictures but there is a good size space between the can and the actual pannier so even when locked down tight it can flex around a good bit. I'll be keeping a close eye on it for a while, might take it out on some logging roads tomorrow, crank down the preload and hit a couple potholes to see what happens.

And thanks, I'm in Kenora.
 

EricV

Riding, farkling, riding...
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#4
Very nice share. :cool:

Good first hand experience and knowledge gained. Thanks for posting it.
 

Clawdog60

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#5
I went and checked again because your question made me paranoid haha but it looks like I have a full 1/2" to the brake line as it sits right now at 20 Celsius so I think I'm ok there.

If anything I'm actually more concerned about the swing arm, I only have about 3/16" clearance to the swing arm but I can't tell if it would be conflicting even if the suspension is bottomed out, kind of a tough thing to test. Best I can tell, even if the can was swollen by the 3/8" and the swing arm did come up far enough to connect, the tapered top of the swing arm would easily push the can over the 3/16" necessary. It's hard to see in the pictures but there is a good size space between the can and the actual pannier so even when locked down tight it can flex around a good bit. I'll be keeping a close eye on it for a while, might take it out on some logging roads tomorrow, crank down the preload and hit a couple potholes to see what happens.

And thanks, I'm in Kenora.
Nice setup. I would have concerns about the 3/16” swing arm clearance. I suppose you would have to be in some extreme conditions to get enough swing arm deflection to nick the pax. Perch bay resort is awesome on the Winnipeg.
 
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