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Suggestions for fixing old ammo box to carry rack?

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thx1138
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PostPosted: 14:19 - 06 May 2016    Post subject: Suggestions for fixing old ammo box to carry rack? Reply with quote
normally have a kriega 5lite dry pack on the carry rack, but I'm going to fix that to the front mudguard now

bought this ammo box from the surplus shop, really not quite sure how to fix it to carry rack

maybe fix marine ply wood to rack with bolts, then find a glue to stick that to box?

drill holes in box, and bolt straight on, but it would really only fit over the big slots, and I'd need super big washers and what not?

or are there strong enough straps, is that an option?

bit stumped really, planning to paint the box with hammerite or similar inside and out


https://img.photobucket.com/albums/v616/THXII38/temporary_zpsx23ol5nf.jpg
https://img.photobucket.com/albums/v616/THXII38/temporary_zpsjwyw3duf.jpg
https://img.photobucket.com/albums/v616/THXII38/temporary_zpsg3eirzec.jpg
https://img.photobucket.com/albums/v616/THXII38/temporary_zpszrwr0qff.jpg
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smallfrowne
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Joined: 25 Jun 2014
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PostPosted: 14:41 - 06 May 2016    Post subject: Reply with quote
Either very big washers or you could span the holes in the rack with some strips of steel with holes drilled in it for the bolts.
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Copycat73
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PostPosted: 17:01 - 06 May 2016    Post subject: Reply with quote
don`t piss about with straps .. been there done that ..

4 x 6mm bolts about 30mm long should do it ... out sized washers and i would put some rubber washers inbetween the box and rack to allow the air in to dry ...

put holes in the bottom of the box and attach to the slotted holes on the rack & box with the washers... and use nylocks ..

try B&Q for the nuts, bolts & washers.
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thx1138
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PostPosted: 17:51 - 06 May 2016    Post subject: Reply with quote
Copycat73 wrote:
don`t piss about with straps .. been there done that ..

4 x 6mm bolts about 30mm long should do it ... out sized washers and i would put some rubber washers inbetween the box and rack to allow the air in to dry ...

put holes in the bottom of the box and attach to the slotted holes on the rack & box with the washers... and use nylocks ..

try B&Q for the nuts, bolts & washers.


thanks, I'll give that a try
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stinkwheel
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PostPosted: 18:04 - 06 May 2016    Post subject: Reply with quote
It's a good plan to use a bit of plywood in the bottom of the box and bolt through it. The metal has a tendancy to split round the edge of bolts/washers you use to attach them.

Funny, I was just looking at doing the exact same thing on my KLE500 for a tool box.

If you put a pop-rivett through from the inside at one end of the hinge, it stops the lid coming off when it's open (look at it and you'll see where).

You'll probably want to take the handle off. They rattle annoyingly.
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Rogerborg
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PostPosted: 19:03 - 06 May 2016    Post subject: Reply with quote
Paper template, mark out these locations.

https://i.imgur.com/TmcNYMn.png

Use the template to drill matching holes in the plate, the box and aforesaid plywood liner. Washers top and bottom, bolts, done.
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Copycat73
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PostPosted: 19:39 - 06 May 2016    Post subject: Reply with quote
stinkwheel wrote:
It's a good plan to use a bit of plywood in the bottom of the box and bolt through it. The metal has a tendancy to split round the edge of bolts/washers you use to attach them.


to do that ... stress fracture ... would require a movement / oscillation frequency ... ..very very unlikely with four anchor points with out sized metal washers and rubber washers with the size of box fitted...
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Last edited by Copycat73 on 19:58 - 06 May 2016; edited 1 time in total
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Copycat73
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PostPosted: 19:49 - 06 May 2016    Post subject: Reply with quote
Rogerborg wrote:
Paper template, mark out these locations.


why put more holes in .. there are way more than enough holes in that rack as it is.. and the slotted holes will make it a lot easier to line up the bolts from the box and fixin it square will be a breez..
if you drill holes in that it will require removing so you dont over drill into the mud guard and to mark the hole position on the underside of the box.. and if you get the centres wrong you`ll be stuck with them..
pluss any more holes will reduce the cross sectional area reducing stress resistance and increasing fracture potential between holes.
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stinkwheel
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PostPosted: 23:07 - 06 May 2016    Post subject: Reply with quote
Copycat73 wrote:


to do that ... stress fracture ... would require a movement / oscillation frequency ... ..very very unlikely with four anchor points with out sized metal washers and rubber washers with the size of box fitted...


I didn't mention is because of some theoretical issue. It happens. It will predicatably happen within 12 months of attaching a standard 5.56mm ball round box to a bike using only washers on the inside. Probably faster on a single.

I've seen it happen to others and I've had it happen myself. I've had 2" repair washers pull out through the side of an ammo box.

They are cheap, thin and nasty metal. It fatigues and splits at stress points. It'll pull a neat circle of metal the exact diameter of the washer out of the box.

A plywood/aluminium insert or a supporting frame has been the accepted way of attaching ammo boxes to motorcycles for decades. You'll find pictures of people having just fitted them with washers but I garauntee they didn't stay on for long.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Copycat73
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PostPosted: 06:20 - 07 May 2016    Post subject: Reply with quote
stinkwheel wrote:


I didn't mention is because of some theoretical issue. It happens. It will predicatably happen within 12 months of attaching a standard 5.56mm ball round box to a bike using only washers on the inside. Probably faster on a single.

I've seen it happen to others and I've had it happen myself. I've had 2" repair washers pull out through the side of an ammo box.

They are cheap, thin and nasty metal. It fatigues and splits at stress points. It'll pull a neat circle of metal the exact diameter of the washer out of the box.

A plywood/aluminium insert or a supporting frame has been the accepted way of attaching ammo boxes to motorcycles for decades. You'll find pictures of people having just fitted them with washers but I garauntee they didn't stay on for long.


thats why i said to use rubber washers between the box and rack..that and to stop water accumulation.
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andyscooter
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PostPosted: 08:04 - 07 May 2016    Post subject: Reply with quote
my way would be two strips of steel or allyhttps://i206.photobucket.com/albums/bb129/andyscooters/TmcNYMn_zpsmjynsgmu.png

drill holes in like this and put strips under the rack drill holes in same place on box and bolt on using washers each side as well
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stinkwheel
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PostPosted: 09:36 - 07 May 2016    Post subject: Reply with quote
Copycat73 wrote:

thats why i said to use rubber washers between the box and rack..that and to stop water accumulation.


A rubber washer under the box won't stop the metal "oilcanning", which is what happens. Especially if it's full of tools. You need something on the inside to spread the load over a wide area. WIder than a repair washer.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Copycat73
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PostPosted: 10:12 - 07 May 2016    Post subject: Reply with quote
well i don`t agree .. the trick is not to over tighten the nuts and bolts.. with 4 x 40 mm or lager washers with rubber between them..
if worried about the metal fracturing rubber washers can be fitted inside the box and underneath the rack giving total rubber insulating.
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iooi
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PostPosted: 17:05 - 07 May 2016    Post subject: Reply with quote
TBH. Given the height compared to the size of the base I would be putting some wood both inside and outside to spread the load over the whole base.
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thx1138
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PostPosted: 14:43 - 08 May 2016    Post subject: Reply with quote
Thanks for all the helpful replies. Will have a go at fitting it on Tuesday, and post pics when I'm done.
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thx1138
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PostPosted: 18:49 - 10 May 2016    Post subject: Reply with quote
Well, I tried.

https://img.photobucket.com/albums/v616/THXII38/temporary_zpstpsnvx8d.jpg
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used a bit of old flotex carpet,
https://img.photobucket.com/albums/v616/THXII38/temporary_zpsprkc73kb.jpg

cut them too small first time
https://img.photobucket.com/albums/v616/THXII38/temporary_zpsg0vayoph.jpg

https://img.photobucket.com/albums/v616/THXII38/temporary_zpso9lyblio.jpg

https://img.photobucket.com/albums/v616/THXII38/temporary_zpsjcblaxin.jpg
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The last post was made 9 years, 228 days ago. Instead of replying here, would creating a new thread be more useful?
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