Hi PappaClutch, The first thing I did was to make a cardboard pattern that bridged the distance between the rack opening. I then sent the pattern to my friend Roy, who transferred the pattern onto some 16 or 18 gauge steel plate. He cut that out and sent the plate to me. I then ground off the rack coating and welded the plate in place. Once cooled, I primed and painted the rack to prevent corrosion. In the meantime, I cut out a larger piece of .75" thick Derlin to bolt to the steel plate to create a stand-off piece to provide clearance from the curvature of the rack. .75" wasn't quite enough of a stand-off so I purchased some .25" aluminum spacers from the local hardware/box store. This created an inch stand-off. The Rotopax mounting hardware could be through bolted through the plate, aluminum spacers, Derlin spacer and finaly the Rotopax mount. If you watch Episode 88, I used a similar technique on Sumo, a KTM 790 Adventure R. The attachment was different, but the same concept. It might help to visualize it. You may also like Episode 14, where I demonstrate how to make your Rotopax deluxe mount tamper resistant. I can provide a picture from the top of the rack which shows the layers in place if you email me at aegismotoadventures@gmail.com. I would be happy to send you that picture. Unfortunately, at the time, I did not think to video the manufacture of the parts like I have done in future videos. I was new to TH-cam and lacked the understanding that people would like to see how things were made. I hope this helps, but if you want more assistance, I would be happy to assist through email the best I can. Take care, Mike
@@aegismotoadventures1616 thank you so much for the detailed response, your awesome! I’d love a picture, I’ll email you. Best of luck to you, stay safe!
Hi, scarfacen8459, Giant Loop tank bags have become our go-to choice. We have had issues with some of their other bags, but the tank bags are top shelf. They are built rugged. The zippers still work - silicon spray helps. The stitching is still intact. I have no reason to believe they aren't a universal fit. They have recently improved the design to make the tank bag more waterproof. We use both versions. We've never had a problem. As a side note, we have no affiliation with the company. Take care, Mike
I'd imagine baggage manufacturers don't use side release buckles because they're not a sturdy or trustworthy buckle. I certainly would not want to trust any kind of significantly weighted luggage onboard to flimsy plastic side release buckles.
Every side-release buckle will have an engineered breaking point. Call me a nerd if you must, but I research these things. Although the buckle is the weak point, manufacturers still use like a D-ring or slide to connect the straps. Split D-rings and plastic slides are still a weak point. Solid or welded D-rings are probably the gold standard, and that is why they still use this system on most helmets- simple and reliable. With that said, the side-release buckle only needs to handle the weight of your gear. If it does that, your good to go. In the event of a crash, well the buckle is the least of your worries. So far they have worked out great for us. But we change if things don't work out.
Can you show how you mounted the tanks to the side racks? I got the same rack system. Thx!
Hi PappaClutch,
The first thing I did was to make a cardboard pattern that bridged the distance between the rack opening. I then sent the pattern to my friend Roy, who transferred the pattern onto some 16 or 18 gauge steel plate. He cut that out and sent the plate to me. I then ground off the rack coating and welded the plate in place. Once cooled, I primed and painted the rack to prevent corrosion.
In the meantime, I cut out a larger piece of .75" thick Derlin to bolt to the steel plate to create a stand-off piece to provide clearance from the curvature of the rack. .75" wasn't quite enough of a stand-off so I purchased some .25" aluminum spacers from the local hardware/box store. This created an inch stand-off.
The Rotopax mounting hardware could be through bolted through the plate, aluminum spacers, Derlin spacer and finaly the Rotopax mount.
If you watch Episode 88, I used a similar technique on Sumo, a KTM 790 Adventure R. The attachment was different, but the same concept. It might help to visualize it. You may also like Episode 14, where I demonstrate how to make your Rotopax deluxe mount tamper resistant.
I can provide a picture from the top of the rack which shows the layers in place if you email me at aegismotoadventures@gmail.com. I would be happy to send you that picture.
Unfortunately, at the time, I did not think to video the manufacture of the parts like I have done in future videos. I was new to TH-cam and lacked the understanding that people would like to see how things were made.
I hope this helps, but if you want more assistance, I would be happy to assist through email the best I can.
Take care,
Mike
@@aegismotoadventures1616 thank you so much for the detailed response, your awesome! I’d love a picture, I’ll email you. Best of luck to you, stay safe!
Did I miss it or what tank bag are you using
Hi, scarfacen8459,
Giant Loop tank bags have become our go-to choice. We have had issues with some of their other bags, but the tank bags are top shelf. They are built rugged. The zippers still work - silicon spray helps. The stitching is still intact. I have no reason to believe they aren't a universal fit. They have recently improved the design to make the tank bag more waterproof. We use both versions. We've never had a problem.
As a side note, we have no affiliation with the company.
Take care, Mike
@@aegismotoadventures1616hi mike, thanks for the reply! appreciate the video
I'd imagine baggage manufacturers don't use side release buckles because they're not a sturdy or trustworthy buckle. I certainly would not want to trust any kind of significantly weighted luggage onboard to flimsy plastic side release buckles.
Every side-release buckle will have an engineered breaking point. Call me a nerd if you must, but I research these things. Although the buckle is the weak point, manufacturers still use like a D-ring or slide to connect the straps. Split D-rings and plastic slides are still a weak point. Solid or welded D-rings are probably the gold standard, and that is why they still use this system on most helmets- simple and reliable.
With that said, the side-release buckle only needs to handle the weight of your gear. If it does that, your good to go. In the event of a crash, well the buckle is the least of your worries.
So far they have worked out great for us. But we change if things don't work out.