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  • 2 Post By revrdmark
  • 2 Post By revrdmark
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Mar 11th 2016, 01:25 PM   #1
 revrdmark's Avatar
  Feb 2016
  Spokane, WA

Cheap Luggage Project

Hi all, so i think that modifying bikes is like a disease or at least a compulsion for me.

I recently sold two Cafe bikes I had built and with the money brought home a 2006 Buell Ulysess. There are so many dirt roads around Spokane i thought i'd take my turn at adventure riding.

The Buell came with two hard case side luggage and a tail case as well. They are in pretty good shape but they are BIG. I decided that i wanted to get something a little smaller for the odd overnight trip or for a quick run to the store or to put stuff for work in when i ride there.

So i priced luggage and didn't want to mortgage my house to buy some smaller boxes. I came across the Ammo Can style luggage in the interwebs and decided that was the way to go. So here is a short write up on the project if anyone is interested.

I bought two Ammo Cans at the local Army Surplus Store (I believe they were 40mm ammo cans) they were on sale for $15 each. So $30 total. They are much heavier than Aluminum or Plastic luggage but they were smaller so the weight was not a huge issue for me. The Ulysses has a rack on it already so i just needed a way to attach the cans to the rack.

The cans would have just been a simple U-Bolt on to the rack but it was angled in such a way that the boxes would have leaned at about a 30 degree angle and i wanted them to be more level. So I had to come up with a way to attach to the existing rack and have a clear place to bolt the boxes to.
KevinD and Arnbo like this.

Edited by revrdmark on Mar 12th 2016 at 02:14 PM
Mar 11th 2016, 01:31 PM   #2
 motoroco's Avatar
  Jan 2016
  Redmond, WA

  Kawasaki Versys, Ducati Monster
Post some pics! I'm interested to see how they scale against the ulysses and how much they contrast with its design.
Mar 11th 2016, 10:41 PM   #3
 revrdmark's Avatar
  Feb 2016
  Spokane, WA

So here is the Ulysses as I brought it home with the Hepco & Becker Luggage on it.

So this is the rack that was on the bike already

I bought about 3 feet of Angle Iron at Ace hardware (Under $10) and cut a few notches in it to rest against the luggage rack, and used simple U-bolts to attache them.

I painted them flat black and used 4 - 5/16 bolts, washers, nylon spacer and a rubber washer (to stop leaks through the bolt hole) to attach the boxes to the rack. I used a big old fender washer to keep the bolts pulling through the side of the boxes and used wing nuts inside the boxes so that i can take them off the rack fairly quickly if i want.

I still need to strip the boxes and paint them black as well

I'll post a few more pictures after i paint them. So between the boxes Angel Iron bolts and washers i spent les than $60 on the whole project.
Arcane and motoroco like this.
Mar 12th 2016, 09:11 AM   #4
 Arnbo's Avatar
  Jan 2016
  Ferndale Washington

  ZX10-R GSXR 600 Track Bike
I have a large assortment of smaller sized ammo cans.
If you ever want to add on let me know and I can get a few to you.
I think the 5.56 can would fit on the outside of the 40mm
Mar 12th 2016, 12:05 PM   #5
 revrdmark's Avatar
  Feb 2016
  Spokane, WA

So rode out to breakfast and the Motorcycle Show with some folks from the forum. It rained this morning so quite a lot of road spray on the freeway and the boxes held up great and were bone dry inside.

I was going to strip the paint off the cans and paint them flat black, but i kinda like the olive drab with paint splotches on it. It has a certain "bad-assery" to it. I'll think i'll keep them as is.

Mar 31st 2016, 12:41 AM   #6
 cool1442's Avatar
  Mar 2016
  North of CDA

  KTM 950 Super Enduro, Honda XR 650R
I did the same set up on a bike several years ago and it worked pretty well and was cheap too. One word of caution I might pass along. I cut hell out of the back of my calf on the lower front corner of the shifter side box in a very slow motion low speed laydown. That corner was sharper than hell! I got a grinder and knocked off the knife edge but it was still pointy. To help out more I laid a bead of silicone along the sharp edges. Never needed band aids again, at least for that prob!
Mar 31st 2016, 03:27 AM   #7
 ZXtasy's Avatar
  Jan 2016
  Moses Lake, WA

  2013 Kawasaki Concours C-14, 2005 ZX-10R Kawasaki (Nekkid), '99 Yamaha TW-200
Good work, looks better IMHO. Maybe a tad heavier but coll for the bike. I did similar with my ADV machine using night vision goggle cans.

See you in the hills!!

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cheap, luggage, project

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