Motorcycle tail storage box mini project#

This mini project was for adapting an MTM ACR7-18 Ammo Crate Utility Box (plastic) to become the locking tail storage box for the Versys 650 motorcycle. The case provides about 14.6 liters weather-tight storage capacity, which, when combined with the Kawasaki hard pannier set, provides me a substantial base of lockable, dry storage for road trips.

Here are the principle components of the project:

  • ACR7-18 ammo box
    • plastic composition, making it easy to adapt
    • features an O-ring seal and sturdy clasps to keep it weather tight when latched closed
    • at the time of the project, it was readily available on Amazon for ≈$20
  • 12mm(.5") thick, 12" x 16" sheet of black rigid PVC
    • serves as the platform the ACR7-18 is glued and bolted to
    • the PVC platform bolts onto the tail-rack mounting brackets (I already had these in place, as I previously had installed an alloy tail rack platform on the bike.
    • at the time of the project, it was readily available on Amazon for ≈$30
  • Stainless steel, die-cast cabinet/drawer lock assembly
    • at the time of the project, it was readily available at Lowes for ≈$9
  • D-rings to serve as tie-downs inside box (from hardware store)

The project steps were as follows (see corresponding pictures below):

  • remove decal from ammo case
  • cut side handles off ammo case -- of no use for fixed-position case and add wind resistance
  • spray paint ammo case exterior black
  • cut rigid PVC sheet to shape to serve as platform for case that fastens to tail rack mounting brackets
  • finish edges of PVC by sanding and then seal edges by wiping on acetone with a rag
  • identify and drill bolt locations:
    • bolts that fasten rigid PVC to tail rack mounts
    • bolts that fasten ammo case to PVC platform
  • fabricate D-ring mounts and rivet into position inside case
  • identify mounting location of lock barrel to enable correct clearance when 1/4 turned (locking position)
  • drill lock location hole and mount lock barrel assembly (I also glued the inner washer in place)
  • install screw that will serve as lock post to angle-iron (aluminum) that will be riveted to case lid (I used thread locker compound on the screw)
  • install angle-iron (aluminum) to lid using rivets
  • identify exact location of notch that needs to be cut in lock swing arm for it to seat on lock-post screw when in locked position
    • cut notch and file as needed to perfect fit and remove burrs
  • glue and bolt case to PVC platform (I put a bead of silicone around bolt locations inside case to assure the case interior remained water tight)
  • bolt platform to tail rack mounting brackets

The ammo case as purchased

View from front of bike of the ammo case fastened to the PVC platform (arrow at A points to the rigid PVC)

The cabinet lock kit (arrow points to position where notch must be cut)

The arrows from A show locations of the tie-down D-rings inside the case

View of lock barrel mounting -- with notch cutout -- inside the case

View of rivet-mounted (B) lock post aluminum angle-iron (with lock post screw, A, in place) in the case lid

View of finished, closed case lid (a rivet location marked by A)

View of finished project from behind the bike