I just wanted some cans to throw a gallon of mik or some groceries from time to time but didn't want to invest in commercial luggage just yet. So I bought a couple of ammo cans from a surplus store for $60. They weighed just under 19#’s each. I started by stripping them down off all the reinforcements and latches/handles, that saved 5#'s a piece. I used the latch rods as hinges and welded them right to the sides of the can.











Since drilling out the spot welds made a mess of the sides of the cans, I smoothed the sides with some body filler and primed.

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'08 Wee

I used 3/16” for the mounting brackets, it’s kind of thick, but it seemed like 1/8” would be too thin and vibrate/bend.



Rear top mount test fit with “ears” to mount the rear supports.



Here are the three mounting points, two on top and one down on the pass foot peg.

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'08 Wee

Since the cans are so sturdy, I used them as an “exoskeleton” and welded the mounts right to the cans. I welded 3/4" angle along the side of the cans and then used 3/4" DOM tubing as struts from the mounts to the cans. That saves weight and the whole assembly can be removed with no trace of having them been installed. I plan on leaving them on there so quick removal was not an issue. Even so, just removing the four bolts for the factory rack and the two bolts down by the peg and the whole assembly lifts off. It all weighs just under 40#’s which is about what the cans weighed before they were stripped down. I haven’t added a rear bar yet, but the structure is so sturdy I might not need to, If I decide to add one, it will have to be bolted on otherwise I won't be able to get the cans off again.

I mounted them a little lower than what I've seen most people, but I didn't want the rear signals hidden. All told I think I have less than $75 into them, went throgh two cans of primer and two cans of satin black.

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'08 Wee

Function IS beauty!


You might need to consider a bolt-in crossbar across the back if you get too much movement back there.

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'12 DL 650- '04 DL 650- '03 DL 1000- '04 R 1150 RT

WERKS modified clutch baskets for DL and SV 1000's.
The BEST in chudder control, noise control, and lasting durability! AVAILABLE HERE: www.werksparts.com
Want straightforward easy to understand answers to clutch basket questions or concerns? E-mail Terry info@werksparts.com

Nice job !

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2007 DL1000 Black (crashed, totaled)
2008 DL650 (wife's sold)
DL650AL2 (Orange) it's Home.....
Exodus 20:17

Nicely done. Nowhere near lame.

Nice job, you got skilz.

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06 DL1000
09 KLR650
95 ST1100

Wow. That looks great. Nicely done sir.

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2009 DL650

Dirigo



LED Marker Lights - Enduro Guardian Skid Plate and Highway Pegs - Custom Tail Bag

Looks pretty damn good to me!

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It's kind of strange, how the mountains pay us no attention at ll. You laugh or cry and the wind just keeps on blowing.

Flint Gray 2002 DL1000

You call this lame? Wait till I post pics of the ones I am building out of aluminium sheet and recycled plastic, you'll puke!

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I'm 40 years old going on 60. Actually I've been going on 60 since I was 20.