Home made top case - secure and lock?

**Wheelie** · #1 3 Nov 2005

I am concidering making my own top case for my vespa to save some money, either from welding one from scratch, or by using ammo cans or something similar (I have made a post regarding the ammo cases on "posts that don't fit anywhere else").

A plane lockable case seems easy enough... However, I have problems sorting out how to make some sort of device that would allow for the box to come on and off the scooter luggage rack in a snap. Also, I want to be able to lock-secure the case to the scooter.

I have done a lot of searching, but I am yet to find what I am looking for.

Any ideas? Pictures? Plans? Comments?

**Matt Cartney** · #2 3 Nov 2005

A while ago I made pannier boxes for my enfield. I made them from 1mm sheet steel and they were very strong. I cut out a template in cardboard first to make sure they 'worked' then followed the template in steel. I folded the sheets by clamping the steel between two bits of angle iron along the part I wanted to fold, secured by g-clamps and then secured in a vice and pushing the steel over with my hands. I then finshed off the fold with VERY light taps with a rubber mallet. Work along the fold with light taps then start again at the beginning. If you try to fold one end right over while the other is only partially bent you'll stretch the steel making getting a flat fold very hard.
I then pop-riveted the whole thing together (dont forget to add flaps for this in your design!) as I reckoned this was far preferable to my rather ham fisted welding! Bathroom sealant in the joins made the boxes watertight. I then had the boxes powder coated. A keyed alike padlock on a standard case latch either end secured the lids. They were not quick release though, but bolted to standard after market frames using u-bolts. Total cost for the 2 boxes including powder coating, latches and locks was about £40.
You could easily do something similar with 'half-hard' aluminium, I'd suggest 2mm.
Matt

**Matt Cartney** · #3 3 Nov 2005

Sorry, just noted you are from Norge! From memory £40 is about 440NK.
Matt

**Wheelie** · #4 3 Nov 2005

Thanx for the folding the metal tip... I was concidering purchasing a separate tool for this, I'll try this out if I go for the home made version.

And yes, 40£ are about 440 NOK...

Anyone got any ideas for "quick release" and locking the box to the rack?

[This message has been edited by Wheelie (edited 03 November 2005).]

**sa6** · #5 4 Nov 2005

hi may i can help you have a metal work shop near th center of Oslo made some box for my africa twin . drop me a line if you want some help.
Regards
Andy

**Wheelie** · #6 5 Nov 2005

Thanks, sending you an e-mail right now.

Still interested in comments and ideas from the rest of you.

Tanks...

**mmclaughlin** · #7 5 Nov 2005

Aluminum Picnic tables also work as decent sheet metal benders. You drop the sheet between two "planks" in the table top and fold your piece of sheet metal over. You have to get a little creative to make a box, but it can work. The bonus is you don't have to buy the table or find a place to keep it.

In regards to securing to the Vespa, if you have a few tabs under the bottom to slide the box onto the rack, just having one or two pins drop down from the inside will keep it from sliding off again. You have to open the box to take it off (open the lid, pull the pin(s), slide the box off), but it is a cheap and simple solution.

Matthew

[This message has been edited by mmclaughlin (edited 05 November 2005).]

**Riq** · #8 5 Nov 2005

I recently mounted a pelican box on the back of my triumph. After finding that the factory box was over $800.00.

I used I bolts and cross bolts to wind up with a box I can install and remove in seconds. You can also instal a lock instead of the hair pin clip that I use in order to gain a more secure situation.

I am sending you an email with pictures.

cheers
Rick

**Wheelie** · #9 6 Nov 2005

Clever, clever, I can really work with this... Thanks

Still interested in hearing/seeing other peoples ideas...

**ozhanu** · #10 6 Nov 2005

Riq, could you also send me the pictures to: ozhanu[at]hotmail.com

thanks in advance

------------------
ride safely
ozhan u.
'97 F650
www.ozhanu.com/gezi

**Hindu1936** · #11 27 Feb 2006

hello riq
could you please send me a photo of your pelican top box? I know you posted in last november, but if you have the photos I would appreciate seeing the idea.
thanks

joe

hindu1936@gmail.com