Gen 2 Trunk Mod
- Thread starter sixpack577
- Start date
any you guys running with a hugger? i see sixpack had to bring it up to 6 inches to avoid rubbing and i am worried that i am going to chew my hugger up if i bottom out. i ride solo 100% of the time.efiguero, i dig the rubber mat idea and i think that will be on my list for tomorrow. i haven't reassembled my bike yet cause it's too damn cold in the garage at nights (-12). i'll wait for a heat wave when it hits the mid 20's.
If you're always riding solo I'de bet you'de be fine at 6". I'm 195lbs with suit and boots, and I've hit some backbreaking bumps and holes without it rubbing. It also hasn't touched with my wife on the back. It only slightly scuffed at 7" deep hitting a deep pothole with her on the back. Go 5" deep if you're concerned, there's no way that's gonna touch, and you'll still gain a ton of room over stock.
I wouldn't be willing to say a definate yes to that. I am confident to say that if you're in the 200lb range and don't have a girl bigger than you on the back
and that your suspension isn't set up so soft as to it bottoms out every bump, that there is no way possible your tire will ever touch a 5" deep box. You will probably also get by just fine with a 6" deep box. 7" deep it's gonna touch slightly at some point. If your box is to deep, simply remove it and trim 1" evenly across the top and rivet it back into place.The only concern is possibly putting a small scuff on top of a tire hugger/rear fender at 6", depending on your set up, 5" should pose no problem. The scuff on the bottom of the box will be minimal and not enough to justify replacing it, unless it makes you feel better. Then you're out another $10 and the time to cut it. Even a 3" or 4" deep box(that will NEVER touch the tire) will gain you tons of space over stock.
cool thanks for the heads up. hopefully, i'll be putting her back together by tomorrow night.If you're always riding solo I'de bet you'de be fine at 6". I'm 195lbs with suit and boots, and I've hit some backbreaking bumps and holes without it rubbing. It also hasn't touched with my wife on the back. It only slightly scuffed at 7" deep hitting a deep pothole with her on the back. Go 5" deep if you're concerned, there's no way that's gonna touch, and you'll still gain a ton of room over stock.
Runinwithscisrs
Registered
Has anyone kept track of the dimensions you cut on this mod? I want to try this but it would be nice if anyone could post up the eaxct cuts they made.
I made a second trunk after the posted original write up. I used a black plastic 3' hefty trash can. It's top is cut to the same shape as the trunk I originally made, only I used the complete bottom, so I have a completely sealed box. From the bottom of the box to highest point of the sides is 4 1/2".
Where the box curves down on the front sides from that height is where it simply follows the curves on the sides of the factory undertail.
My original trunk was only 1" to 1 1/2" deeper(can't remember exactly) I hit a deep pothole with the wife on the back and got a very small scuff mark from the tire. Other than that it never rubbed. I just went a little less deep on the second to make sure it never rubbed again, and it hasn't.
Let me know if I can do anything else to help you. Several other members who were nervous or skeptical to try this found that once you're into it, it's very easy and straightforward and works well.
Nothing could fall out of the first design, it bolted flush at the rear of the undertail. There were very, very small gaps on each side of the rear(sides, not bottom) that I sealed with silicone. Had I been about an 1/8" more precise it would have been a non issue, but it was early in the am when I finished up the first.
The second trunk was only done because of a light rubbing issue with a passenger hitting a deep pothole, so I wanted to try one not quite as deep.
I thought the second time around I'de use a trash can bottom as opposed to the file box. The trashcan seemed to be more durable plastic and the outer corners weren't as bulky as the file box. It was just more simple to drop in a completely sealed box, as opposed to the extra effort it took to make sure the original 3 sided design was a precise fit(inside of the tail itself and inside of the taillight was the rear wall on the original, with part of the box floor folding up and into it, and using 2 of the 4 tail bolts to secure the rear).
I decided on the correct depth(4 1/2", and you actually have more than this due to clearance above the top of the factory undertail's sides).
Then I cut the curves into the front top edge matching the shape of the factory undertail(that allow the seat/hump hooks to move into position).
The trashcan was just cut down from it's original 3' height, the curves cut into the to the front corners, dropped in, and riveted to the factory undertail's sides and it was done.
Make sense?
Man I so wanna do this but I'm skeered 
wash that poor girl, geez.
And clean the garage too !
busa1300nut
Registered
Great Idea! And very nice work.. I think I would run into rubbing issues on my gen1, since I have it set pretty low. The extra space will be very nice.
Thanks, and it just depends how you make the box. You can gain space on a lowered gen1, it's not much, but it can be done.
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