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[puregreen59]

Hey guys, this is my first post around here

I'm buying a 2017 zero sr, but I need to fabricate my own arms to hold a large delivery box,  so my question is the easiest way to make welding safe, I will need to be able to weld at least a few of the parts while attached to the bike, and I don't want to blow anything up, and dismantleing the entire bike to remove the sensitive equipment is kinda out of the question unless no other options remain, can anyone give me some pointers, cheers! 😁👍

[mdjak1]

How heavy is the stuff you will carry in the box?   The factory rear rack is pretty strong and maybe if you need more strength, you might get the side case rack pieces and combine them together.

[TheRan]

One option would be using some nylon bolts and washers to isolate the rack while welding, and of course replacing them with steel once it's all done.

[Shadow]

What is the concern here? Are you welding to the aluminum frame, or just tack welding things into position around the frame as a reference?

[TheRan]

He's going to be bolting things to the bike's frame and then welding other bits to those, and he's worried about causing damage to any components that would be electrically connected (not insulated) to the frame.

[pacificcricket]

EMF can be a bit of a concern, not the electrical discharge itself. I would suggest running a ground wire from a well-known grounding source to the frame of the bike. Note that this is a concern primarily around operational digital components that remain powered when bike is not in operation - EMF can cause for them to reset and get stuck in a bad state.

[puregreen59]

Thank you for your replys guys, good idea with the nylon bolts, what a great tip! I think that will be my game play just to be on the safe side.

As for weight, the box it's self weights around 8kg let alone the the arms and hardware, then of course anything I put in there, to get a good idea, on my current fosil burning bike I can get a level large shopping trolley in there. So weight wise depending on what I carry I need it to be very robust.

As for getting the side racks and welding to them I was planning on just making it mount the the back of the pillion pegs and then a truss between the two

[NoMoreIdeas]

I'm looking to make a custom aluminum subframe for the FX to house an additional charger and have always wondered this myself. Even just tacking things together. In theory, everything is isolated from the chassis so it 'shouldn't' be an issue. I like the nylon fastener idea though.