avon gripster back tire....size problem?

[Jeff Khoury]

Good Morning, Since one of the requirements for owning a KLR is being cheap, I thought I'd post my Sunday project on my '09.. I had been getting by with a duffel bag strapped to my luggage rack and I'd always wanted a hard top case. The problem is that purpose-made top cases are frikkin' expensive and the ones that I've seen really don't look like they belong on a KLR. My requirements were: It had to be tough Must be waterproof Look like it was meant to be there Sunday morning, off to the surplus store I went. In the back room I found a pile of surplus IFF interrogator cases. They're made of some kind of magical, really-tough plastic and have a rubber gasket on the lid. They close with 6 180-degree turn latches and it even has a pressure-release button. I guess until I drilled mounting holes in the bottom, it was not only waterproof, but airtight. They are a perfect fit for the '08+ KLR luggage rack. I removed the foam inserts and drilled holes to match the bolts on the luggage rack, and got some longer bolts to fasten it down. I then sanded and painted it with spray-on bedliner for a tough, industrial look. I plan to line the inside of the case with the thin, gray carpet that they cover speaker cabinets to keep the contents from rattling around. Here are some pictures of the completed install: http://www.facebook.com/photo.php?pid=30396383&l=01b7d5e59f&id=1121850447 http://www.facebook.com/photo.php?pid=30396384&l=8d5481641e&id=1121850447 http://www.facebook.com/photo.php?pid=30396386&l=c3993f0738&id=1121850447 Cheers! -Jeff Khoury [Non-text portions of this message have been removed]

[n9udl]

Here are some docs for your case! http://www.globalsecurity.org/military/library/policy/army/accp/ad0575/lesson1.htm

--- In DSN_KLR650@yahoogroups.com, Jeff Khoury wrote: > Sunday morning, off to the surplus store I went. In the back room I found a pile of surplus IFF interrogator cases. They're made of some kind of magical, really-tough plastic and have a rubber gasket on the lid. They close with 6 180-degree turn latches and it even has a pressure-release button. I guess until I drilled mounting holes in the bottom, it was not only waterproof, but airtight. They are a perfect fit for the '08+ KLR luggage rack.

[RJ]

I wish I could mount a couple of those on the front of my KLR to thin out some of the deer here in Minnesota. Ross Lindberg Fertile, MN

--- In DSN_KLR650@yahoogroups.com, "n9udl" wrote: > > > > > Here are some docs for your case! > > http://www.globalsecurity.org/military/library/policy/army/accp/ad0575/lesson1.htm > > --- In DSN_KLR650@yahoogroups.com, Jeff Khoury wrote: > > Sunday morning, off to the surplus store I went. In the back room I found a pile of surplus IFF interrogator cases. They're made of some kind of magical, really-tough plastic and have a rubber gasket on the lid. They close with 6 180-degree turn latches and it even has a pressure-release button. I guess until I drilled mounting holes in the bottom, it was not only waterproof, but airtight. They are a perfect fit for the '08+ KLR luggage rack. >

[Jeff Khoury]

Tom, When drilling the bolt holes, they line up with indentations in the case... it is not on a flat section, but the material is such that flexion does not cause the material to crack, so I put a little blue Loctite on the threads and cranked them down a few turns so as to make them tight, but not "too tight". I used some regular washers and the bolts were 6mm-1.0x30mm with a 10mm head. Here is a picture of the mounting bolts: http://www.facebook.com/photo.php?pid=30396664&l=b9b2c8c1d9&id=1121850447 -Jeff Khoury Astatic Solutions, LLC.

----- Original Message ----- From: "n9udl" To: "Jeff Khoury" Sent: Monday, October 12, 2009 10:16:12 AM GMT -08:00 US/Canada Pacific Subject: Re: Top case on the cheap Hi Jeff, I think it looks great! I notice that the side (bottom) of the case isn't flat... How well did the contour line up with the mounting bolts? Did you use fender washers or fab a bracket of some kind? Thanks! Tom --- In DSN_KLR650@yahoogroups.com, Jeff Khoury wrote: > I removed the foam inserts and drilled holes to match the bolts on the luggage rack, and got some longer bolts to fasten it down. I then sanded and painted it with spray-on bedliner for a tough, industrial look. I plan to line the inside of the case with the thin, gray carpet that they cover speaker cabinets to keep the contents from rattling around.

[Jeff Khoury]

Quick update: I found this case on the internet at colemans... The design is the same and the dimensions are correct, it is probably just labeled differently. The usual disclaimer applies about buying surplus stuff, quality may vary. Mine was fairly scratched, but the bedliner spray took care of the scratches quite nicely. They're $19.95. http://store.colemans.com/cart/aviators-kit-boxcontainer-heavy-duty-plastic-p-261.html -Jeff Khoury

----- Original Message ----- From: "Jeff Khoury" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Monday, October 12, 2009 9:10:52 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Top case on the cheap Good Morning, Since one of the requirements for owning a KLR is being cheap, I thought I'd post my Sunday project on my '09.. I had been getting by with a duffel bag strapped to my luggage rack and I'd always wanted a hard top case. The problem is that purpose-made top cases are frikkin' expensive and the ones that I've seen really don't look like they belong on a KLR. My requirements were: It had to be tough Must be waterproof Look like it was meant to be there Sunday morning, off to the surplus store I went. In the back room I found a pile of surplus IFF interrogator cases. They're made of some kind of magical, really-tough plastic and have a rubber gasket on the lid. They close with 6 180-degree turn latches and it even has a pressure-release button. I guess until I drilled mounting holes in the bottom, it was not only waterproof, but airtight. They are a perfect fit for the '08+ KLR luggage rack. I removed the foam inserts and drilled holes to match the bolts on the luggage rack, and got some longer bolts to fasten it down. I then sanded and painted it with spray-on bedliner for a tough, industrial look. I plan to line the inside of the case with the thin, gray carpet that they cover speaker cabinets to keep the contents from rattling around. Here are some pictures of the completed install: http://www.facebook.com/photo.php?pid=30396383&l=01b7d5e59f&id=1121850447 http://www.facebook.com/photo.php?pid=30396384&l=8d5481641e&id=1121850447 http://www.facebook.com/photo.php?pid=30396386&l=c3993f0738&id=1121850447 Cheers! -Jeff Khoury [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Don Montgomery]

Hal, I have a 130 and now that you made me look at it real close, it has a hairs clearence with the muff. There is no evidence that the tire has been rubbing the muff but it might be a good thing to add a nut and a longer mounting bolt as a spacer between the subframe and muff hangers if it doesn't stress the header pipe. I suppose the tire might get hot but not dangerously so. I don't know what the OEM clearence is with the factory supplied tire, maybe it was a 120. The clearence at the front curve of the swing arm is close but no sign of interference. Don M

----- Original Message ----- From: Norman Moore To: Don Montgomery Cc: DSN_KLR650@yahoogroups.com Sent: Friday, October 09, 2009 2:10 AM Subject: Re: [DSN_KLR650] Avon Gripster Back Tire....Size problem? Don, I found out I had a 130 Back Tire, as opposed to a 120. The Kawa Dealer suggested a 120 Gripster next time but said I was good to go after a little tweak. Which width do you have? Plus I did have it a little tweaked and an old chain. I have never, to my recollection, had any problem with this after installing a new tire..... the tolerances on the swing arm are close at the front curve of the arm, regardless of the muffler situation. Hal ------------------------------------------------------------------------------ From: Don Montgomery To: Norman Moore Cc: DSN_KLR650@yahoogroups.com Sent: Thu, October 8, 2009 7:53:49 PM Subject: Re: [DSN_KLR650] Avon Gripster Back Tire....Size problem? Hal, I have run through several back ones with no notice of clearence problems. Is your chain in line w/ the countersprocket? Can't remember if there are any spacers that could end up on the wrong side, seems the brake disk would not fit into the calipher if so. Take a hit on the muff and bend it in some? Swing arm twisted a bit so as to angle the tire to the right side? Mis-manufactured tire? Head scratch, Keep us posted. Don M ----- Original Message ----- From: "Norman Moore" To: "Jeff Khoury" Cc: Sent: Friday, October 02, 2009 1:44 AM Subject: [DSN_KLR650] Avon Gripster Back Tire....Size problem? > Has anyone run into a problem with the Avon Gripster Back tire being > almost too fat for the KLR650 muffler? It seems to have very little > clearance and tends to make the right edge of the tire hot.....or is it > just my bike ( I have full Givi Bags). > > I may have tweaked the chain adjusters, maybe? Anyone else have this > problem? > > Hal > > [Non-text portions of this message have been removed] > > > > ------------ --------- --------- ------ > > List sponsored by Dual Sport News at: www.dualsportnews. com > List FAQ courtesy of Chris Krok at: www.bigcee.com/ klr650faq. html > Member Map at: http://www.frappr com/dsnklr650Yah oo! Groups Links > > > [Non-text portions of this message have been removed]