DIY topbox rack

[nowhere.elysium]

Since I've had to spend a bit of time at work today, I figured I'd do something that actually served a purpose too. As such, I decided that I'd had enough of not having a topbox actually mounted to my luggage rack, so I set about remedying this.

Much time was spent fannying out getting the measurements of the luggage rack, which is a royal PITA the model, since it doesn't appear to have much by way of straight lines in the design of it.
https://farm4.staticflickr.com/3914/15039626550_5e9471c5b5_c.jpg

This is the best approximation of it that I could manage, which was close enough for the next step.

From that, I put together a basic design for a mounting plate. I decided that I was going to have two layers, because it's easier for me to recess bolts so they're hard for thieving sods to get to if I can sandwich them in the middle of the thing; more on that later.
https://farm4.staticflickr.com/3867/15226283925_9196c2972a_z.jpg

https://farm4.staticflickr.com/3855/15039709807_a915c5f9d5_z.jpg

Single red lines are profile cuts - pretty much outlining the edges, and the bits that look filled (they aren't, in truth, but it's a low-res image, so meh) are area clearance paths: the cutting head goes back and forth and clears the area, as the name would suggest.

So, save the file, and export the G-code.

This unhelpfully shadowy image shows the first stages done:
https://farm4.staticflickr.com/3840/15203246996_b80dee6d18_b.jpg

Then we start outlining stuff:
https://farm6.staticflickr.com/5590/15226281875_bae70316cf_b.jpg

A bit more outlining:
https://farm4.staticflickr.com/3903/15039502359_30cbfca359_b.jpg

On a largely unrelated note, the hood that's covering the routing bit was something I designed and 3D printed a while back:
https://farm6.staticflickr.com/5585/15225905062_4db2e17f1c_b.jpg

https://farm6.staticflickr.com/5560/15039830568_46b3015666_b.jpg

Anyway - back to business. I fitted a set of coachbolts in the recessed holes, so I can sandwich the whole thing together a bit later: for now, I wanted to see if everything lined up OK with the rack.
https://farm6.staticflickr.com/5556/15039598250_7090e6923f_b.jpg

https://farm4.staticflickr.com/3853/15039502179_7253ff40f8_b.jpg

Satisfyingly enough, it would appear that I am met with success.

What remains to be done now is designing and printing a set of brackets with captive nuts, so I can mount the baseplate on to the rack properly. When I've got those successfully prototyped and working, I'll machine the final version out of this weird resin-based material that I inherited from the workspace I'm now in, and make a tidier and more finished-looking product.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[mintex]

Looking good so far mate

[Just_James]

I need one of those machines

[blackbosh]

Awesome, love little projects like this just don't have the resources to make bigger stuff, otherwise the missus would have some proper grab handles

[nowhere.elysium]

[Just_James]

[kramdra]

... so square bit of wood with 5 holes in it.. that your going to make again with resin plastic?!


If that was my workspace I would sell your tools and buy CNC mill/lathe, tig welder and a furnace for casting alu parts

[nowhere.elysium]

You're more than welcome to post something more interesting, if you consider it so inferior. Regarding the tools, these are what I use at work. The lathes, mills and welding gear are next door.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[Matt B]

[map]

[nowhere.elysium]

Well, despite the commentary from the guy who doesn't understand the process of prototyping, I've continued work on this. I've now designed in a recess that follows the line of the rack, to add that extra bit of stability to the design, which will be properly complemented with the clamping plate when I've finished; I'm mainly looking at stripping out any excess material that isn't needed at the moment, due to the weight of the final material.
https://farm6.staticflickr.com/5591/15069718687_e10f13fdba_b.jpg

I should have a bit more to show later on today.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[mentalboy]

Impressive stuff - Especially that extractor boot! I've never seen one with brushes before, is that common in joinery shops nowadays or totally your own idea? (I'd have thought if so that you would have a market for that - or have I totally missed the 'now marketing extractor boots' thread?)
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Make mine a Corona.

[nowhere.elysium]

No, they often come with brushes now; definitely a good thing, since the prototype's being done in MDF, and the dust from it is nasty stuff.

That reminds me actually, I really ought to put the design on thingiverse or somewhere similar.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[nowhere.elysium]

Overrated? I has a sad.

Moving onwards, I've now put together the designs for the upper and lower plates, with the recesses for the actual rack cut into them:
https://farm4.staticflickr.com/3837/15258115495_cf4f6bc095_b.jpg
https://farm4.staticflickr.com/3916/15071557768_80f8362461_b.jpg
https://farm4.staticflickr.com/3857/15235108026_7eb3fedba9_b.jpg
https://farm4.staticflickr.com/3892/15071428430_e191cdc7e4_b.jpg
https://farm4.staticflickr.com/3889/15071427680_b22606e27f_b.jpg
Having assembled the plate and test-fitted it on the bike rack, it's become clear that there needs to be a bit more space around the corners in the enclosed area, so I'll be re-cutting that, as marked out below:
https://farm4.staticflickr.com/3909/15257717332_a7874d317f_b.jpg

For those who are unsure as to why I'm going through such a laborious prototyping process, it's because I'm using this as an example project for the BSc Product Design students; ordinarily, I'd happily just measure stuff up first time and refine it with a file, if needs be.

Once this iteration's done, I'll sort the final bolt alignment for the topbox locating pins, set them in place, and that should pretty much be it. I'm also going to work out a decent weight reduction pattern to rout out of the plates themselves, because the material is pretty dense, as has been previously noted.


:edit: I've since modified the design to account for the bits that need trimming out and will trial this one before adding the anchor points for the bolts.
https://farm4.staticflickr.com/3897/15071764958_76fa7ec8d8_b.jpg
The large circles are also going to be routed out in the same manner as the channels from the previous version.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[sidewinder]

Good job.looking forwards to the end result..

[nowhere.elysium]

We have a contender - it fits the rack now, just got to align the mounting holes, then I can print up the lugs for the topbox to attach to and cut the final version.

https://farm4.staticflickr.com/3880/15235781666_16586bf844_b.jpg
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[STONEY!]

Dont get me wrong here, I like making stuff and I am impressed with your hood design and all the cool machines. .....buut why are you making a top box plate when you can buy one for £20-30 with a box that will fit straight on your rack? Wondering if I have missed something or is it just because you can in which case fair enough

[nowhere.elysium]

[P.]

If you can work out a way for me to mount a top box without buying a spare seat and drilling through the pillion area for my triple, I pay you mega pounds

[Just_James]

[SQL]

[P.]

I have the top box and mounting plate... however I r spastic

[nowhere.elysium]

[nowhere.elysium]

Double post madness
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[P.]

I may be in France however I shall have bike there if I do attend so you can have a nosey. Givi do one, but it requires mad £££ and taking shit apart. 2 things I could do without with this bike