Disposable Versys Pallet - Kawasaki Versys Forum
 
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post #1 of 20 (permalink) Old 06-12-2011, 09:26 PM Thread Starter
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Disposable Versys Pallet

I'm helping my girlfriend move from Houston to El Paso. I'm going to stay there a few weeks, so I wanted to bring my bike with me, and ride it back home. The 26' Penske doesn't really lend itself to tying down a bike, so I decided to palletize it for more secure transport. I'll drive it onto the truck. maneuver it on to the pallet and tie it down once we get the truck. Then once it's offloaded, I'll dispose of the pallet. Right now, I'm just testing whether my workmanship was strong enough to support the bike.

Materials were:
Countless 2.5" wood screws
4x 2x4s
8x Rubber furniture feet
4x 325# screw eyes.

I cut two 2x4s into 6' lengths.

I attached them 8" apart screwing the 2' scraps onto the ends.

I cut one 2x4 in half and attached the 4' lengths flat on the bottom of the ends of the main work piece to form an I shape.

I cut the last 2x4 into 10 smaller pieces for supports. four 1' pieces, four 3.5" pieces and two 8" pieces with scrap left over.

I used four 1' pieces to screw into the top of the 6' and 2' pieces to keep them from pulling apart when the bikes weight is inside the box.

I screwed four 3.5"x3.5" pieces into the tops of the ends of the 4' pieces. These will help anchor the eye screws.

I screwed two 8" pieces at a 45 degree angle in either end of the box to make cycle removal easier and to put less pressure points of the tires.

I mounted the eyelets on the reinforced ends of the 4' pieces and the rubber feet to the bottom of the 4' pieces.

Thats the best I can explain it. Mine isn't exactly to specs on cuts, but I didn't put a whole lot of effort into it, as it's disposable, and it just needs to be strong.













I use a metal wheel chock to load it into the box, it's easier to remove than load on. I plan on securing the pallet to the truck as well as stacking properly around it. I also intend to coat it in a furniture blanket.

If I was going to add something to this design I would double up 2x4's on the 4' end pieces instead of just reinforcing the areas where the eyelets go. I would also screw in cross members on the bottoms of the 6' pieces to strengthen that area. Probably one ladder rung every 16". However, since this is being tossed in a dumpster once I'm done with it, I didn't want it to be to strong and unbreakable. I also didn't want to invest in more 2x4s or screws than I had. I do plan on reclaiming the eyes after I'm done, for future use. This way only 15$ worth of screws and wood gets tossed.

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post #2 of 20 (permalink) Old 06-12-2011, 09:59 PM
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good idea

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post #3 of 20 (permalink) Old 06-12-2011, 10:01 PM
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Your girlfriend is moving to el paso? Is this the end of a relationship or the start of a long distance thing.
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post #4 of 20 (permalink) Old 06-12-2011, 10:06 PM Thread Starter
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Originally Posted by rumbo75 View Post
Your girlfriend is moving to el paso? Is this the end of a relationship or the start of a long distance thing.
She's going to medical school out there. She lives in the same town I do, but she went to undergrad in Maryland, so it's always been a long distance thing. I'll probably move out to El Paso once I finish school, my undergrad is taking forever because I work full time and go to school. We plan to definitely move to the same place once she determines her residency.

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post #5 of 20 (permalink) Old 06-13-2011, 02:01 AM
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It's a great design. I would reinforce the 2 beams that lie flat against the floor that is perpendicular to the main beams. Nail a column so that the flat piece would look like an 'L' from a X-section view. I.e, what u got now is not a full 'L' and my suggestion is to make it a full 'L'. It look like it may bend under constant heavy loading, and wood being wood, may just warp permanently under moisture exposure and cause the cable tie to turn loose.

For testing, perhaps sit on the bike while it is being locked down, rock left and right and check for any weaknesses that may have been exposed.

And all the best for the journey. I wish I have wood working skills like yours.

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post #6 of 20 (permalink) Old 06-13-2011, 10:12 AM
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It looks like it will work.....I would put it nearer the front of the truck for a smoother ride, and perhaps over near a wall. It it were to get loose, it would just "lean" against the wall without much issue. You could put the mattress on one side, and the box springs on the other and create a padded pocket of sorts for it to hide in.

Oh, keep it near empty on the fuel................


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post #7 of 20 (permalink) Old 06-13-2011, 01:56 PM
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I built something similar out of a wooden pallet...worked (works) well!... In the Ya'll Haul truck I slide the rig all the way to one side up front, cover the bike with a bunch of soft quilts and then pack clothing stuffed in lawn and garden bags (aka "60 piece luggage set") all around and up the sides. cozy.... discovered on one move that a strap had fallen off! the bike was so snugged in with quilts and the clothing bags that it stood on its own without any straps at all!!!! and no rub marks anywhere. Have a safe trip and good luck!
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post #8 of 20 (permalink) Old 06-13-2011, 02:10 PM
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Nice work!

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post #9 of 20 (permalink) Old 06-13-2011, 03:24 PM
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Quote:
Originally Posted by snarky View Post
She's going to medical school out there. She lives in the same town I do, but she went to undergrad in Maryland, so it's always been a long distance thing. I'll probably move out to El Paso once I finish school, my undergrad is taking forever because I work full time and go to school. We plan to definitely move to the same place once she determines her residency.


Sorry for being so nosy but it's the first thing that came to mind.

Pallet looks awesome!
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post #10 of 20 (permalink) Old 06-13-2011, 04:17 PM
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Would it be easier to rent a trailer with the truck?
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post #11 of 20 (permalink) Old 06-13-2011, 04:35 PM Thread Starter
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Quote:
Originally Posted by 2daMax View Post
It's a great design. I would reinforce the 2 beams that lie flat against the floor that is perpendicular to the main beams. Nail a column so that the flat piece would look like an 'L' from a X-section view. I.e, what u got now is not a full 'L' and my suggestion is to make it a full 'L'. It look like it may bend under constant heavy loading, and wood being wood, may just warp permanently under moisture exposure and cause the cable tie to turn loose.

For testing, perhaps sit on the bike while it is being locked down, rock left and right and check for any weaknesses that may have been exposed.

And all the best for the journey. I wish I have wood working skills like yours.
Yeah, I originally wanted to make it a full L, but I didn't want to go buy anything other than I had. If I was going to do this again, I would make that area a full L and double up those beams. I might build another one of these when I get back from El Paso for use on my trailer. I wont have to worry about any moisture exposure too much, this pallet only has to last 2 days before being tossed.

I attached the bike and stood on it, rocked it back and forth, dragged it around with a dolly, couldn't tip it over, or loosen the straps. The fun part will be driving the bike on to the truck, and then driving it on the pallet while it's on the truck.

Quote:
Originally Posted by zgfiredude View Post
It looks like it will work.....I would put it nearer the front of the truck for a smoother ride, and perhaps over near a wall. It it were to get loose, it would just "lean" against the wall without much issue. You could put the mattress on one side, and the box springs on the other and create a padded pocket of sorts for it to hide in.

Oh, keep it near empty on the fuel................

Yeah, the way gasoline expands, I don't want to fill the truck with too many fumes, especially with how hot it is and being bumped around in a moving van. I'll probably drain the tank this week when I do the sparkplugs, and add just enough fuel to get it on and off the truck and to a station, . It'll be in the front passenger's side corner, strapped to the wall, with the kick stand down. That way it'll either come to a rest on it's kick stand, or the handlebar and pannier will rest against the wall. That way there won't be any damage if it comes loose.

Quote:
Originally Posted by Rik View Post
I built something similar out of a wooden pallet...worked (works) well!... In the Ya'll Haul truck I slide the rig all the way to one side up front, cover the bike with a bunch of soft quilts and then pack clothing stuffed in lawn and garden bags (aka "60 piece luggage set") all around and up the sides. cozy.... discovered on one move that a strap had fallen off! the bike was so snugged in with quilts and the clothing bags that it stood on its own without any straps at all!!!! and no rub marks anywhere. Have a safe trip and good luck!
Rik
I worry a bit about my eyelets pulling out or a strap loosening for no reason, as they tend to do. I'll stack large stable furniture around it, and cover it with a moving blanket. The way I dog the Penske, my poor bike will need all the help I can get. With the panniers, barkbusters, and crash bars, I figure it'll probably survive any fall well enough.

Quote:
Originally Posted by rumbo75 View Post


Sorry for being so nosy but it's the first thing that came to mind.

Pallet looks awesome!
No problem, I know it sounded weird after I posted it. Wait, your moving your girlfriend to the desert and not going with her?



I plan on posting a video of the Versys being loaded on the truck via being driven up the ramp, then tied down. It'll either work great, or be tragic. I'll tell you what though, I'll be in full gear... lol.

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Last edited by snarky; 06-13-2011 at 04:38 PM.
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post #12 of 20 (permalink) Old 06-13-2011, 04:51 PM
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I always thought the more gas you have in the tank, the less fumes there will be.

Be careful driving it up into the truck. Seen a few youtube videos of people crashing while doing that. Maybe it would be better to walk it up with the help of a couple people or use the engine but walk next to it rather than just ride it.
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post #13 of 20 (permalink) Old 06-13-2011, 10:34 PM
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Ditto the danger of dropping the bike while getting it onto the truck. If you have very long legs, that danger is lesser. Would be good to have an additional helper nearby, just in case.

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post #14 of 20 (permalink) Old 06-13-2011, 11:44 PM Thread Starter
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Quote:
Originally Posted by 2daMax View Post
Ditto the danger of dropping the bike while getting it onto the truck. If you have very long legs, that danger is lesser. Would be good to have an additional helper nearby, just in case.
I'll have someone nearby to help and someone to film the crash. I have no worries, I've got long legs, and the plan is to take the ramp at a stable speed. It's an all or nothing kind of thing. Walking it up the ramp just removes the inherent stability of the bike. I learned this when driving my XT225 up and down my hitch rack on the back of my truck, and that's a much narrower ramp to traverse, though half the height.

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post #15 of 20 (permalink) Old 06-15-2011, 10:27 AM
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I helped my brother load his in a Penske truck. I used a sheet of plywood and bolted a front wheel chock and four tiedown points to it, then screwed the whole thing down to the wooden truck floor with short drywall screws. Nobody ever noticed the tiny screwholes afterwards.

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post #16 of 20 (permalink) Old 06-17-2011, 08:02 PM Thread Starter
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I didn't bother with the video. It was flipping hot. Heres a picture or two.



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post #17 of 20 (permalink) Old 06-17-2011, 11:20 PM
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Now I get the whole picture of the idea how it worked on the truck. Thanks. But how do you plan to unload the bike from the pallet? I imagine it would be tough to roll over the member unless there is a triangular ramp like nailed to where the tires need to roll over the beam.

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post #18 of 20 (permalink) Old 06-18-2011, 09:33 AM Thread Starter
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There is an angled piece screwed under the tire. It comes off quite easily. I plan on muscling the pallet 180 degrees and driving it off.
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post #19 of 20 (permalink) Old 06-20-2011, 11:58 PM Thread Starter
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Well the bike made it to El Paso no problem. I had a bent a pannier bracket a little bit due to misplacement of the ratchet strap, but that was my own fault, not a problem with the design. Just wasn't paying attention when I attached that one, I was able to fix it easily by ratcheting it the other way.

Also when disembarking the truck, I almost ****ed up by putting my foot in air rather than on the ramp. However, after a scream and quick readjustment, all was well. El Paso is a crazy place to ride. It's a lot like certain parts of Houston, where people just make up their own rules on crossing roads and pulling out. Just have to be alert and cautious.

The damn A/C in the Penske went out, in the summer, in the 105 degree heat. We check the freon and it was fine, so we rigged the A/C compressor to allow us to directly engage via a power wire off the alternator and a switch. It gave us a bit of cooling, but you had to manual decide when to engage and disengage the compressor to keep it from losing cooling ability after a while, or freezing up the evaporator core, which would stop the air flow.

Made it from Houston to El Paso via Penske.

Next journey will be motorcycle from El Paso to Dallas/Ft Worth. Then DFW to NYC and back via airplane.
Then I go to DFW to Toronto and back via air plane, and I ride my bike back to Houston.

Then I fly to Seattle for an Alaskan cruise, where I hope to rent a KLR at somepoint, then I eventually make it back to Houston.

Finally, I drive back to DFW and then drive to Ruidoso, NM for a family reunion, and eventually drive back to Houston.

I log a lot of mile on trucks, bikes, planes, and boats this summer. If I can get a train trip from Houston to New Orleans, Ida be all set for types of vehicles.

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post #20 of 20 (permalink) Old 06-21-2011, 12:02 AM
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Email me when you get close to Seattle, might have a bike hookup for you. Are leaving from Seattle or Bellingham?
Bob

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