Right, I now have all the boxes and the hoops for my 3AJ, to begin the assembly of my luggage system. I went for the xXx boxes and the Zega topcase, with the Touratech hoops. It can all be seen on the following images:

www.geog.ucl.ac.uk/~lmiller/topcase.jpg
www.geog.ucl.ac.uk/~lmiller/sidecase.jpg
www.geog.ucl.ac.uk/~lmiller/sidecase2.jpg

You can see that the side cases are reinforced at the top and the bottom edges (just like the Tesch boxes?) and have seals inside. The lids pivot on the NARROW side and have the same locks as the Zega-Top. The lids are also fully removable without tools...

I am really happy with the quality of the equipment, and I have more than enough space! Unfortunately Ernie is booked up until March or later, so I may have to wait a while before the racks are finished!

What do you think?

Cheers!

** Looks like the UCL server's down at the moment (23:46 GMT 27/11/02) so I can't check those files. Let me know if you see them **


[This message has been edited by POB/London (edited 27 November 2002).]

The files are all up and running: what d'you think? I have to work out how to fit them now!

Looks great,good luck fitting them.
You started out with better luck than me,I ended up making my own rack to take Givi luggage,and it looks like I'll have to make some crash bars and a front carrier too.
B.t.w, where arre you heading and when are you going?
Griff.

Looking good Lewis,
I am in the process of making my racks up at the moment(or should I say I am helping my girlfriend's father make them for me : ) ), using touratech hoops as part of the mainframe.

However, I have gone for the soft option (Oxford Sports panniers), with an ex-army ammo case under each one, mounted on their sides, to hold the tool kit and any valuables/breakables not going in the tankbag.

I am considering lining the pannier's with a light mesh to make them a bit more slash proof.
WIll let you guys know how I get on over the next couple of weeks and send in some pics.

Griff, have you got a design for your crash bars yet? If so, could you email me a copy?

Geoff

ps. Lewis, I called X-bikes today on your reccomendation, it made a change speaking to somone who knows a bit about XT's. Will be taking my bike to Chris sometime this week.

Your hoops are the same as mine then? I was going to weld some flat bar onto the subframe, and then use a 6-point bolt-on subframe on each side for the cases, with a brace behind the number plate (although I will take the plate off and rivet it onto my topbox I think ... less likely to break w/ rocks). This will all be made from mild steel thick-wall tubing. Although the joints will all be welded, the frames will bolt on, and therefore be removable. I think a major fitting point will be the passenger footpeg hangers actually. Perhaps I will have a play in photoshop and post up a rough geometric plan (like I did with the frame strengthening article...)

I also considered soft bags, but with some of my journey in Eastern Europe and quite a few valuables, I couldn't take the risk. I can also use hard cases at home! I think Dan Walsh (from DiRE magazine) used soft cases and found them OK, although burning is a major issue I think. CS recommends a small lockable tool case on the rear carries as well - your ammo cases sound perfect for that.

I think I am a bit out of the ordinary, in that I want to avoid using a tankbag. I have never liked them, and will instead use a duffel on the seat behind me, with a map case on the 'bars. This should be fine with my GPS and stuff.

I can also rig up a bag over the screen, fender-bag style. A headlight guard / front rack would be great, but shipping from Riky Cross is outrageous. Will get my G/f to get a quote (she lives and works near Turin). Perhaps we can club together to buy some stuff?? Re: making your soft bags slash-proof, you can buy (from YHA and other places like that) special mesh with lockable closures, designed to fit over backpackers bags for just this purpose. Look into that, and save yourself some work.

I think I have bought some 2nd hand crash bars for a 3AJ from australia (!) and so you're more than welcome to copy the design if / when they ever arrive. A guy I know had them, and they ceased fitting his bike when he added a kick start. I am going to graft on a small jerry can rack onto each side, to carry water and fuel. Will let you know, but engine and TANK protection is vital, esp. on the twinlamps.

Good to hear you called X-bikes. My friend has had his engine back - great work but very expensive in the end. I don't think the parts were cheap... Unless you stress that it's urgent, I think Chris also tends to <ahem> take his time!

Let me know, whatever. Perhaps we should meet at some point? I am based very near to Greenwich, and ride into London (on the XT of course!) every day.

Hi there!

Boxes look good - so how much are they (normal retail) and where can I get xxx-boxes...

The Touratech wouldn't be my option, but OK.

Try welding on some hooks on the xxx...

I've just made racking for a 3AJ loosely based around a Touratech type central loop. I have extended the lower rack mounts to the frame, not the pillion footrest hangers, as the footrest hangers are not very rigid.
Could send you pictures, if that would help you decide how to do yours?
Wouldn't mind seeing pictures of your engine bars when they arrive, please.
Good Luck
Neil

Geoff,
No e-mail address in your profile,mail me at link above in my profile
In answer to your question,no,I have'nt got a design for the crash bars yet but I do have one for the rack(takes Givi)if you want to see it and get the spec I will send it to you along with costing.Re Oxford soft luggage,I took some to Europe earlier this year and the snap locks broke,leaving my luggage bouncing down an embankment into a field.I have read other reports of people crashing and one person being killed because of this too(although Givi were found unaccountable at the trial), and so this is why I decided to take hard luggage this time.

[This message has been edited by GRIFF (edited 04 December 2002).]

email address removed by Grant - see http://www.horizonsunlimited.com/ubb/faq.shtml#notify for why.

[This message has been edited by Grant Johnson (edited 04 December 2002).]

Thanks Lewis and Griff for your info,
sounds like I need to update my profile.

I don't get much chance to use the net during the week, so will reply to the two fo you personally on the weekend.

geoff

OK - I bought the boxes from Moto-Ward in Surbiton, Surrey. Their website is here:

http://www.motoward.co.uk/

... and they seem quite helpful with looking at microfiches and getting UK part numbers etc. The xXx boxes I got were excess stock I think, so good luck in finding them.

I didn't buy the TTech frames, just the hoops, since they're hard to weld up. They will be used as the basis for a home-made system. (By the way, I won't using the footped mounts as such, just their holes in the frame - that wasn't clear...)


Off to Italy now (Turin), see y'all next week.

Hi Neil,

I'm about to weld up a rack for an XT600 and wouldn't mind seeing pictures of yours if its no hassle. Have got a 20litre jerry can for each side (fuel and water) as am planning north africa. Was going to weld up two rectangular frames the size of each can and fix to pillion footrest hangers, exhaust mountings/ frame and a hoop round the back. Then sling soft luggage on top. Any thoughts much appreciated.

Thanks, Finian

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PS. Am also interested in group purchase of bits from abroad.

Finian

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Finian -
You'll have to wait, I'm afraid - off to Africa tomorrow! My racks include mounts for two ten litre jerrys - 20 litres ones are a bit bulky for my taste.

Back mid-Jan, drop me a line then.
Neil

What the hell are you guys carrying? Are you in the transport business?

I used two pieces of bent steel 25mmx4mm. They run from the rear rack to the pillion footrest mounts. Each has four bends in it and holds my oxford sports panniers off the rear end, stops the exhaust setting them on fire and strengthens the rear sub frame. Each pannier is 18l and that was all I took except for a chain bag and a 10l rucksack. I covered upto 500km off road without refuels on a 1vj and and did over 2000km of off road riding with full sleeping kit. Cost, £1.50 steel from B&Q ( it was a sunday andI was desperate!), £30 panniers!

My advice, don't get carried away!
photos available....

Dave

Neil, Griff and Dave,
would you mind sending me photos of your racks please?
I still haven't made mine due to my bike being in the garage and am now running out of time.
Neil, I brought engine bars from Motoward this weekend.
They still have one or two left and are trying to get rid of them. (£60)
Geoff