Smuggler in the works

[kieefjr]

EDIT, 1/2022
New link for photos;

https://postimg.cc/gallery/0rzZcJn



In the want ads some of you may have seen my homemade smuggler made off the rear seat pan that I have for sale along with the remains of a 05FJR.



This was very handy on my 2005 since I'm a solo rider and don't care much for tail-boxes.

I've decided to build one for my 2013 model. I put the first layer of glass on it today after cutting a cardboard form and covered it with slick tape. A stock seat pan is also used as the base.
I put Johnson's paste wax over the tape and went to glassing.
https://postimage.org/

[LKLD]

This should be interesting!

[kieefjr]

Got the box and seat pan fiberglassed today.



Next will be cutting a hole in the top box and mating the seat pan mold into the box after trimming the edges, then fiberglass the two together. When that is done I'll have two parts, the box and stock seat pan and then I'll be able to bolt the two together.

Theres a lot of work still to do after that. Glad the temps have be decent around here.

[HotRodZilla]

Cool! Watching!

[Gramps]

What's the pie plate for? Support?

[kieefjr]

What's the pie plate for? Support?

No, that's my resin mixing pan, .99 cents at GWill.

Once the base is attached it will be pretty solid.

I will fiberglass in some washers to where it bolts to the seat pan and where my lid will hinge.

[Gramps]

Ahh, got it. Enjoying watching the process.

Sent from my XT1097 using Tapatalk

[thompsonian]

Ohhhh...looks very interesting!

[gixxerjasen]

Looks good. I've been itching to play with fiberglass over the years. (See what I did there?) Just never have actually done it though. I hope you keep posting pics of the build, I love seeing these kinds of things come together.

[kieefjr]

This is a fun project especially when the weather is funky. I built the last one while I was out on medical leave for knee surgery.

I should make some progress this Wed and Thurs..
Thanks for the comments.

[kieefjr]

Today I clean the edges up on the seat pan mold and drilled the holes for securing it to the seat https://postimage.org/

Then I fitted the box over the pan while on the bike and clamped it place once it looked square.
I used my saber saw and cut out the opening then its back to the bench to do some more glassing.
I sealed the seams on the inside first and let it dry for a few hours and then I removed the clamps, rechecked the fit on the bike and unbolted the box from the seat pan.
It sits now on the bench upside down with the outside seams filled and any gaps covered.

https://postimage.org/

[kieefjr]

I needed to a little more f-glassing. The bottom edges were not thick enough and I wanted them to extend a bit past the seat pan. So I did that and filled in a couple of other flaws.
Today I clean all that up, sanded any high spots down and mounted it back on the bike to make sure everything was hunky dory. I also opened up the access hole a little bit.

The next step is apply Bondo all over the outside surface. I'll sand it smooth and repeat the process until I get a nice smooth surface acceptable for painting.

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[gixxerjasen]

I'll bet you have nasty crusty boogers after all that sanding!!!

[kieefjr]

I'll bet you have nasty crusty boogers after all that sanding!!!

I could put them on a t-shirt and mail 'em to ya if you like?

[gixxerjasen]

No thanks, I have plenty of my own.

[kieefjr]

I've been sanding reapplying bond and sand some more. Weathers been pretty good, nice breeze even though its a bit chilly.
Bondo work done for this part just applying putty to small imperfections.
https://postimage.org/app.php

Spray painted it with a type of primer with filler, show ups the imperfections better.
https://postimage.org/

Next step is the lid. Same act, make a mold out of cardboard and glass it.

I also filled the inside seams between the base and box with a sealer because a coin or small object would be hard to get out. Now the inside is pretty much flat.

Its bit late now but I should have installed the stock rack to make sure it would this fit a stock bike. Hopefully the Givi rack will follow the same lines as the stock rack. If not, well I'll be SOL.

[LKLD]

Starting to take shape...looks good!

[escapefjrtist]

Fun project and nice work!

--G

[Hppants]

Looking good - keep going!

I take it that since you used the rear seat pan, the smuggler will be removed/installed just like the seat is? Also, are you planning to make the contents of the smuggler waterproof, and if so, how? Would you anticipate it being able to hold the weight of a camping bag?

Just curious, and thinking....

[kieefjr]

Looking good - keep going!

I take it that since you used the rear seat pan, the smuggler will be removed/installed just like the seat is? Also, are you planning to make the contents of the smuggler waterproof, and if so, how? Would you anticipate it being able to hold the weight of a camping bag?

Just curious, and thinking....

It's bolted to the seat pan, pops off just like the seat. I bought another seat/pan on eBay, I wanted to keep my stock seat as is and like the one on my 05, I'll most likely never use it again.

The other one I built was waterproof and this will be too. The lid keeps any moisture out. I was going to use something like a rubber seal under the lid but never did. I've been caught in showers and washed it without any contents getting wet.

I made this one a little lighter than the 05 one, it's thinner but strong. I believe you could fill it with rocks and not have a problem. Only concern would be it breaking off the mounting holes to the seat pan but that's an easy fix. You also could add more f-glass in the seams to make it as strong as you like.

I use it for my camera, water bottle, hat, something to throw my gloves and glasses in at a quick stop, food, ect.