Custom racks and top/side cases - Kawasaki Versys Forum
 
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post #1 of 11 (permalink) Old 06-28-2009, 04:19 PM Thread Starter
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Custom racks and top/side cases

I've been working on building a rack and case system since before I even got the bike. I finally finished putting it all together today. The top rack was put together on a template, but the side racks had to be welded together with brackets attached directly to the bike because of the complexity of the geometry (precautions were taken to protect the bike during welding).

The cases attach to the racks using 3 compact machined aluminium brackets and matching inserts that incorporate a lock. Inserts attach to the cases using a steel plate with extra anchor points for nylon straps. All cases are interchangeable. The large cases are Nanuk 940 (36 litres each) and I have a 4th smaller Nanuk 915 top case (13 litres). Nanuk cases are similar to Pelicans, but I find the latches much easier to operate and the cases more aesthetic.

I did a small test ride this afternoon and nothing budged or made a noise so I'm very happy with the results. The cases are positioned to clear the angle at which the footpegs would touch the ground while staying as close as possible to the axis of the wheel and low to the ground for stability and balance. Wind drag doesn't seem to be a problem either.

I will have the aluminium brackets anodized black later on. Next up on my To-do list is a set of crash bars. I may also heat form the top of one of the larger cases to be able to fit my helmet inside.

Last edited by jonny2001; 07-25-2009 at 10:44 PM.
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post #2 of 11 (permalink) Old 06-28-2009, 04:30 PM
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That is extremely well done. I can see that took a huge amount of preparation and thought. I really like the case attachment/lock mechanism.

Very impressive!

Chris in Oneonta, NY
08 Versys that replaced my beloved 07 KLR650


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>>>> states on a bike <<<<
>>>> East Coast done <<<<
>>>>> Westward HO! <<<<<
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post #3 of 11 (permalink) Old 06-28-2009, 06:13 PM
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Wow, very nice.
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post #4 of 11 (permalink) Old 06-28-2009, 06:58 PM
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Great write up and even better fab work. Are you planning on painting the cases? The white does not look right to me. I'm looking forward to see what you make for crash bars.


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post #5 of 11 (permalink) Old 06-28-2009, 09:13 PM
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Gorgeous!
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post #6 of 11 (permalink) Old 06-29-2009, 01:17 AM
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very awesome!!
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post #7 of 11 (permalink) Old 06-29-2009, 04:45 AM
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farkle well done!!!!!!
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post #8 of 11 (permalink) Old 06-29-2009, 01:32 PM Thread Starter
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Thanks for the compliments. I picked white for visibility, but they're also available in black, grey, green, etc. I'll probably stick some reflective tape on the sides. I would have liked to paint something and apply retro-reflective glass beads, but the cases are Polypropylene (or Polyethylene, can't remembre) so paint won't stick very well.
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post #9 of 11 (permalink) Old 06-29-2009, 01:41 PM
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I can't blame you for going with safety over looks.


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post #10 of 11 (permalink) Old 10-02-2009, 07:40 AM
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Pics, please. Tks.
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post #11 of 11 (permalink) Old 10-07-2009, 08:33 PM
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I don't see any pictures.
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