How to Mount Pelican Boxes for Side Cases
Pelican cases mounted on a motorcycle can protect property from theft, severe weather, or damage during a collision. Boxes can be mounted to the rear or sides of a motorcycle by purchasing a prefabricated kit and tweaking it to accommodate the cases. Mounts can also be constructed using raw materials to custom-fit the storage cases. Individuals with appropriate tools, resources and skill often prefer to tailor custom mounts that suit their needs.
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Things You'll Need
- 4 strips of 1/8-inch by 1 1/2-inch steel
- Aluminum flat bar stock
- Plastic welding
- Waterproof tape
- Black silicone adhesive
- Aluminum channel
- 16 gauge 3/4-inch square tubing
- Drill
- 3 flathead bolts
- Locknuts
- M8 Allen Head bolts
- Weld
- 4 locking wire pins
- 4 keyed padlocks
- Aluminum cross brace
Instructions
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1
Bend the four 1/8-inch by 1 1/2-inch steel strips into brackets that can be attached to the bottom bolt of the rear passenger holds and the bolt for the turn signals. Measure the cases and mount the brackets so they are spaced correctly to accommodate the size of the box. Line up the Pelican cases with the brackets to be certain there is enough clearance for the rear wheel.
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2
Prepare the cases for mounting by sealing the holes in the cases using bar stock, plastic welding, waterproof tape, or black silicone adhesive. Do not seal the holes that are located between the two ridges on each end of the backside; these holes will be used to assist in securing the boxes to the mounts.
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3
Weld four strips of flat aluminum channel lengthwise to the bottom of each case -- two inside the case and two outside. Drill three holes through the channel that will be used later to attach the cases to the bike.
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4
Using the size of the cases and distance between the brackets as a guide, construct rectangular frames by welding 16 gauge 3/4-inch square tubing together. Use two additional pieces of square tubing to weld "fingers" to the frame that will snugly fit between each pair of ridges on the backside of the case. Drill holes through the fingers that line up with the ridge holes. Tack the frames to the brackets.
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5
Insert three flathead bolts through the channel strips on the case assembly and secure with locknuts. Drill through the entire assembly at the threaded mounting points and attach the case to the rack with M8 Allen Head bolts.
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6
Weld one finger to the top of each frame that will rest against the backside of the taillight to help hold the frames in place. This will also help prevent the cases from sliding during travel. Weld the aluminum cross brace to the bottom edge of each frame. Test to be sure that the cross brace will completely clear the rear tire at full suspension compression. Bend the cross brace as needed to achieve full clearance.
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7
Secure the Pelican case to the brace by threading locking wire pins through the holes drilled in the fingers and case ridges. For the upper bolts that go through the handles, drill through the bolt and use a butterfly nut drilled for safety wire, with a paperclip twisted through them, to prevent them from backing off due to vibrations.
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Tips & Warnings
Radiator stop leak can be substituted for bar stock.
Wear proper safety equipment when welding.
If the cross brace is not checked before riding, damage can be caused to the rear tire during suspension compression.
References
Resources
- Photo Credit Jupiterimages/Photos.com/Getty Images
