DIY Pelican Motorcycle Top Case

Mixing things up a bit here with a more motorcycle-centric post. Recently I fashioned my own top case to Murdock, my F800GS Adventure and here is a walkthrough on how I went about it.

To preface, I love my bike and everything about it minus the fact that parts and accessories can be ridiculously expensive for it. A problem that I was running into was having a secure storage space that would be permanently affixed to the bike for whenever I would commute or carry valuables. Normally I only run my Mosko Moto side bags when I go on longer trips since they add to the width of my bike making it a little more challenging to split the heavy California traffic. I do have a pair of tail bags meant for the sissy-bar of a Harley (hey, you use what resources you have available to you) but it didn’t have much storage capacity nor was it securable from the casual thief or the elements. Yeah, the big aluminum hard cases are nice but the $480 + $200 mounting rack to get one is a bit overpriced in my opinion.

After some quick research, I opted for mounting a pelican case on top of the existing stock luggage plate. Pelican cases 20170421_171956are durable, waterproof, and a lot cheaper when compared to their aluminum counterparts. I bought this Pelican 1500 with foam off of Amazon for $106. Hardware from Home Depot was about $6 and I already had all the tools needed. I went with the 1500 case due to its size both internally and externally on the bike. Could I have gotten a bigger one? Yes, but I don’t necessarily need anything bigger. If your storage needs are different though, the steps I took will apply to any sized plastic case that you decide to go with.

After getting the Pelican case, I made a quick trip to Home Depot to pick up some longer bolts, large washers, and some silicone sealant. Don’t overthink this step, as its really whatever you can make work. I ended up taking one of the stock bolts for the rear 20170421_184737.jpgluggage plate with me so that I could match the threads. Most hardware stores that I have been to have a handy gauge near the nuts and bolts where you can try fitting what part you already have into the gauge. The stock bolts are 55mm long and the ones I got from Home Depot are 65mm long. Large washers are a must as they help diffuse the pressure from the bolts across a larger area on the plastic of the pelican case so that the bolts don’t end up pulling through on all the bumpy roads you go down. The silicone, though I haven’t applied it yet, is to make the pelican case waterproof again after drilling through the bottom of it in the mounting process.

The hardest part of the whole project was finding the center line on the bottom of the pelican case due to its rounded corners. I used a tape measure and a square to find the center line, centered the stock luggage plate off of that line and used it as a template for marking the holes to drill. I highly recommend drilling pilot holes with a smaller drill bit so that you don’t end up marring the bottom if the drill bit were to jump around trying to get started. The drill bits went through the plastic like hot butter so be slow and deliberate when drilling.

 

20170421_192027.jpgAfter drilling, its a quick and easy mount onto the rear of the motorcycle. I still used the stock luggage plate underneath the pelican case to provide extra support and rigidity. If I were to get a larger luggage plate in the future, the holes in the case would still line up with the motorcycle. My thought is that I will probably end up getting a larger luggage plate sometime in the future as it would be handy to have easier points to hook straps to underneath the pelican case in order to secure luggage over the top and sides of the case.

With the case foam, I removed all of it for while I was working on getting the case mounted. After it was mounted, I put in the top and bottom pads and tore out the center foam so that I would just have the outer ring. I plan on having my electronics, breakables, and valuables in this case more often than not and don’t necessarily want them rattling freely around the case without some padding. Yes, I would have more storage space inside the case if I didn’t have any foam at all, but if I need more room then I can just pull out the foam again.

 

Overall, I’m extremely pleased with this project and how it looks on the bike. Its cheap in comparison to going out and buying a pre-made hard case, is rugged, and is lockable with a padlock style lock at either corner. So if any of you are thinking about doing the same, I hope this article helps.