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[PWM]

Happy to share more details once this project gets assembled - at the moment it's a real struggle to find sourcing for the following:



Can someone (please) recommend a sheet metal shop (west coast usa preferred) that can provide decent price for single piece quick delivery?

Everyone I've contacted in my area is slammed quoting killer lead-times.

Just a hint...compromises made were difficult but carefully chosen...

Seat is not altered and no longer pivots on the bike - it is removed for charging.

Tail-light relocates under top box mount for obvious safety concerns.

No frame modification - only tail fairing piece gets hacked and that was easy for me...had a paddock stand mishap in garage and caught the bike going down but stressed / broke pivot point on fairing.

Prior to the mishap I was convinced mounting a top box was not feasible...



/Steve

[Demoni]

There are a number of online services that offer low volume quick turnaround time laser cutting services.

https://www.oshcut.com/ These guys appear to also offer bending.

Would love to see a side shot of the box on the bike. Do you have any sketches for the planned support structure?

Here are some photos of a SS9 with custom brackets to allow mounting of a Givi plate and rack. Only other bike I have seen with a top box was a EVA107 that built off the saddlebag brackets.

[rick danger]

just cant warm up to that erector set looking piece along the seat bottom on this bike. Is there any reason for those holes? Or was that a design choice?....nothing to do with the topic, but the pic made me think of it.

[PWM]

Mounting plate arrived and fit is good but decided support method planned is NG, meaning not strong enough...there's nothing to grab onto in the rear frame w/o welding...



Removed image for content not relevant to final outcome.

[Demoni]

The base plate turned out really nice, clean bends good edge finishing. I'll remember Ballard for any future sheet metal projects.

The 4 bolts that secure the plate holder are attached to m6 bosses welded to the subframe. They are one of the mounting locations used for the side bags. Not sure of the total load rating with your setup, so be cautious. I will say that the aluminum plate carrier is not designed to carry a load or possible fatigue from vibrations.

I agree that mounting points for triangulation are limited on the rear of the bike. It's one of the reasons the ss9 rack I posted has those square tubes.

[PWM]

The 4 bolts that secure the plate holder are attached to m6 bosses welded to the subframe. They are one of the mounting locations used for the side bags. Not sure of the total load rating with your setup, so be cautious. I will say that the aluminum plate carrier is not designed to carry a load or possible fatigue from vibrations.

Yes, direct attachment to the subframe at the location indicated makes good sense and I agree current setup will be prone to metal fatigue over time which is something I didn't want to hear.

Okay, trial #3 then...

[PWM]

This is the third swing and it looks right...credit Demoni.



Thin walled steel tubing from the local Home Depot - it has potential for looking tits comparatively speaking.

[Demoni]

Nice!

A lot stronger attachment point for sure, also looks really clean!

[PWM]

A head nod of approval is appreciated - thank you. 

Intended payload is modest, take-out food and work computer are the drivers to making bike companion grade.

Wide angle view for brake light is not compromised, you don't happen to know source for wiring connectors do you, Domoni?

I rather make an extension cable than hack the pigtail on the light assy - it is super nice quality and even after taking off the tamper proof fasteners one finds it isn't serviceable w/o damaging seal.



Post project image insert...re: seat restraint, rear...

[Demoni]

you don't happen to know source for wiring connectors do you, Domoni?

The connector for the brake light is a JST jwpf style. You can find them through Digikey and Mouser.
Intended for high quality 22AWG wire. Lower quality wire using thicker PVC insulation may cause issues.

The factory crimp tool is prohibitively expensive for a hobbyist. I have found this tool can create successful crimps:
https://www.amazon.com/gp/product/B00YGLKBSK/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

[PWM]

Could not wait for USPS to deliver connector parts shipped 2/22 priority mail so hacked the tail-light cable just to get back to riding.

For broasted chicken there's no better than Scotties...a 40-mile round trip for take out and the only mission is keep it warm...


Dang this bike now has great utility and still retains its good looks and great performance...the top box mount is rock solid doesn't shake rattle or...I'm a happy camper closing this thread and thanking the good folks that run this forum for allowing such indulgence...



Of note - some thread posts are now deleted that contained eye-sores for design attempts made prior to the one that took hold and again big thank you to Demoni for the oversite in getting here - it's appreciated.

[EVriderDK]

PWM:

Seat opens perfectly?
I will first try to fit my tail bag on the bike. It is one of the TanklockED bags with a key. If I can make a good solution then I will just use that, but if not, then your option seems great, and also I could fit a passenger.
Do you have som drawings for the design?

Thanks

[Hans2183]

Nicely made on that grey Ribelle. Is it only attached to the the fender extension mounts? If more strength is needed you can use the passenger pegs, those points are combined on the official side case rack.