Cheap-n-easy system case upgrades

[frankenduck]

1) ELASTIC REPLACEMENT FOR GEN 3 CASES: Replace the cheap flimsy BMW elastic with 1/4" bungee cord. In hindsight, 3/16" would probably have been easier to install and adequately strong but 1/4" is what I had around. It takes about 10 feet of bungee cord to do a pair of system cases. Cheaply bought on eBay and will outlast the BMW stuff by a country mile. Run the cord through the attachment points and washers and then tie a figure 8 knot in the end so it can't pull through. Figure 8 knot:

UPDATE 2/18/12:  I did a couple more sets of the Gen 3 system cases this morning.  Since I may end up doing it again I measured what the right lengths of 3/16" bungee are:

Top elastic: 13 1/4"
Bottom elastic: 16 3/4"

You'll need four of each which conveniently comes out to a total length of 10 feet of 3/16" bungee cord to do a left/right pair of system cases.  And also a total of 16 1/4" washers. (5 cents each for stainless steel)  Also, once you've cut the bungee cord melt the end with a Bic lighter and roll it in your fingers.  This keeps the outer fabric of the bungee cord from unraveling and makes it easier to get it through the washers and the mounting holes in the system case.

2) RETAINER PANELS: When I started real touring on my K75RT, I got sick of crap falling out when opening the system cases on the road with the cases on the bike. One day an inspiration hit me and I made some retainer panels. I used white board that I had left over from a home message board project. I now have them made out of clear plastic.

3) CARGO NETS: You can buy bungee cargo nets from BMW. 46542315916 is the part number for the kit.  You need to order two - one for each side.

Or you can make your own using 3/16" bungee (cheap on Fleabay) and some small zip-ties:

[Turkus]

Neato, FD !!   ;)

I just might try somewthing like that on the MotoBoxer as mine will get tired eventually.

I just blew up one of the retractors on the outside lid and I'm afraid to ask BMW what they want for one of them.
Maybe a 3/16" bungee from Harbor Freight will make an adequate replacement that won't interfere with my Cee Bailey insert bags... ;D

[ibexonabike]

Was going to post this in the workshop, but this seems a more appropriate thread. Is there an alternative to the $50-as-new replacement gaskets that seal the lids to the bases? I was thinking of ordering some material from McMaster Carr and rig something up, but if someone else already drank the cool-aid ...

[frankenduck]

Was going to post this in the workshop, but this seems a more appropriate thread. Is there an alternative to the $50-as-new replacement gaskets that seal the lids to the bases? I was thinking of ordering some material from McMaster Carr and rig something up, but if someone else already drank the cool-aid ...

I think some black rubber hose of the same diameter would work fine.  IIRC, DrxBMW replaced the seals on his city cases that way.

[frodef]

Franken: That knot link is 404 it seems.

[frankenduck]

Franken: That knot link is 404 it seems.

Thanks. Fixed.

[dwerbil]

Thought I'd add this cheap security mod to the thread. Pic is from a '80 R80RT.
Probably could retrofit this mod to their K bike.

A friend added two 1/4 x 20 bolts with nuts to his saddlebag racks that would
match drilled holes into the bags to which wing nuts were added. End result is
that the bags are bolted to the bike.
Anti-theft, anti-fall off.....

[frankenduck]

Here's a set of clear acrylic retainer panels that I made this morning.  I used a Plaskolite Optix 18" X 24"  X 0.220" Safety Sheet (Product # 1AG2123A) that I picked up at Lowe's for $20. (You could probably use 1/8" thick acrylic but this is what they had on hand.)

I'm not sure what the "right" way is to cut this stuff and round off the corners but I use a metal cutting blade on a table saw.

By the way, if you're ever moto-camping and need an ice cooler:

[mystic red]

I'm not sure what the "right" way is to cut this stuff and round off the corners but I use a metal cutting blade on a table saw.

Scroll saw would do it nicely.

[Lawrence]

The gaskets on my tired old tragkorbs were shot, so I went to Home Depot and found some generic insulation strip.  It was made with groove in the middle, which I used as a guide to cut it lengthwise into two strips.  One fits perfectly in the groove of the lid.  Cheap and easy!