Little custom work - Rear Wire Bundle Sollution

[StarFan]

I have often wondered why in the world Yamaha cramped all these electrical wires in that crummy little triangle space in the rear of the bike behind the license plate. Had been wondering if this could be done any other way and this is what I came up with.

Decided to make a box that had space enough. So I went and did some measuring,,,,,,,,,,,,,,,,,,

Have the Harley Brake light frame in the back so I decided to make a box that would fit in there and have the same angle as the Harley frame. Had a company here in Iceland make this out of stainless steel and opted for not going mirror steel since it would be hard to get at and clean. Then they said they had the box electro polysomething whatever that meens - but looks pretty good.

What I like about this is that it is very easy adding and hooking up any wires for future accessories and I feel better knowing that the wires are not bent and cramped in a tight bundle.

 

Note that the Icelandic license plate is huge compared to yours in the US. Have orderted a private plate with my choice of inscription and am gonna brake the law and have a friend of mine make a copy that will be US size. I will just keep the original in the trunk if I will be pulled over.

Pictures attached:

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2423_zpsbf61601b.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2412_zps874a49ea.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2413_zpsab9d1831.jpg

 

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2417_zpsfa0c239f.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2427_zpsb042dc95.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2433_zps0ca7526d.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2432_zps3eaccd3d.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2431_zpscd091dd8.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2429_zps35b057d9.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2428_zps4d047d1b.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2434_zpsb35d59ac.jpg

 

http://i1281.photobucket.com/albums/a501/jonaslill/Connection%20Box/SAM_2436_zps0f36d5be.jpg

[wrenchrob]

Hey that looks really good. Very neat

[Bert2006]

Wow nice and tidy...good job:thumbsup:

[M61A1MECH]

Jonas,

 

Very nice, looks good. Did you put something around the inside of the hole where the wires come thru so they do no chaf and cut the insulation?

 

That "electro polysomething" is probably electropolishing it is a method of removing burrs and small hangy things that are often left on metal parts after working them such as cutting, drilling or tapping also improves the overall finish of the part, here is a link to wikipedia about it. http://en.wikipedia.org/wiki/Electropolishing

[billmac]

Sooo what did it cost you for the box. Looks good.

[StarFan]

Jonas,

 

Very nice, looks good. Did you put something around the inside of the hole where the wires come thru so they do no chaf and cut the insulation?

 

That "electro polysomething" is probably electropolishing it is a method of removing burrs and small hangy things that are often left on metal parts after working them such as cutting, drilling or tapping also improves the overall finish of the part, here is a link to wikipedia about it. http://en.wikipedia.org/wiki/Electropolishing

 

Yes, there are rubber grommets to protect the wires.

 

Sooo what did it cost you for the box. Looks good.

 

Don´t know yet. But guess it is not gonna be less than 300 US$. This kind of work is expensive here in Iceland.

[coop]

Hey Jonas,

 

Nice job on the box.... very neat and looks great with the extra lights.

 

We were working on the same thing this weekend but I was going the other way.

 

I put a different laydown, curved license plate holder on the bike and had to cut and solder all of the joints in there to cram everything in even a smaller triangle ) And went with shttp://i15.photobucket.com/albums/a385/bobn/Star/NewLicensePlateHolder.pngmaller lights ) Oh boy...now everyone can see when lI last had my bike inspected 07!

 

Bob

[cowpuc]

BEAUTIFUL JONAS,, JUST FLAT OUT BEAUTIFUL!!!!

 

I ran into a situation like that once with an old beat up Cushman Scooter that the guy didnt like the original junction box so he redid everything using an Allen Bradley commercial 3 phase disconnect box,, had lots of room for terminating wiring but looked no where near as nice as your job did!!

 

NICE JOB!!

[bongobobny]

Nice mod Jonas!!!

[cecdoo]

Looks great Jonas! You could put a hinge on the top of the license plate and have enuff room in the box to stuff a thin bike cover! Just kidding Buddy!

 

Craig

[StarFan]

Bob, that is one special nice bike you have there to say the least. What a gem..... Great mods.

What in the world did you do to the front of the saddlebag lid ? Got any pictures ? This is interesting to say the least. I would like to make mine wider by a couple of inches but I think it is a little tricky to do so I am putting that on ice for now.

Hey Jonas,

 

Nice job on the box.... very neat and looks great with the extra lights.

 

We were working on the same thing this weekend but I was going the other way.

 

I put a different laydown, curved license plate holder on the bike and had to cut and solder all of the joints in there to cram everything in even a smaller triangle ) And went with shttp://i15.photobucket.com/albums/a385/bobn/Star/NewLicensePlateHolder.pngmaller lights ) Oh boy...now everyone can see when lI last had my bike inspected 07!

 

Bob

[WillyB]

Excellent job! Looks great!

[coop]

Bob, that is one special nice bike you have there to say the least. What a gem..... Great mods.

What in the world did you do to the front of the saddlebag lid ? Got any pictures ? This is interesting to say the least. I would like to make mine wider by a couple of inches but I think it is a little tricky to do so I am putting that on ice for now.

 

Hey Jonas... thanks! I fiber glassed speaker pods to hold a 6" component set. Some pictures below

 

http://i15.photobucket.com/albums/a385/bobn/Star/FiberglassinaSaddlebag.png

 

http://i15.photobucket.com/albums/a385/bobn/Star/SaddlebagPods017.jpg

 

http://i15.photobucket.com/albums/a385/bobn/Star/leftlid-1.pnghttp://i15.photobucket.com/albums/a385/bobn/Star/LidCloseup-1.png

 

http://i15.photobucket.com/albums/a385/bobn/Star/DSCF0727-1.jpg

 

This picture isn't the latest....windshield & tach is off, carb extender not on and the flying goddess on the front fender is taped.... I'm trying to get comfortable with her first.

 

Bob

[coop]

Last One

 

http://i15.photobucket.com/albums/a385/bobn/Saddlebagsfromfront-1.png

[coop]

Jonas,

 

Your saddlebags can be widened. You would have to mark them out and split the right up the center.... bags and lids. ABS plastic require a lot of prep to make sure you get good adhesion. 24 grit sanding wheel and 1/8" holes on the area that will be accepting the glass. It's a good 50 hours worth of work if you have fiberglass experience..... if not you might want to double that.

 

I'd buy a spare set of bags to do the mod with so you'll always have your stock bags to put back if you ever need to.

 

I'd be more that happy to walk you thru the process if you decide to do it.

 

Bob

[StarFan]

Jonas,

 

Your saddlebags can be widened. You would have to mark them out and split the right up the center.... bags and lids. ABS plastic require a lot of prep to make sure you get good adhesion. 24 grit sanding wheel and 1/8" holes on the area that will be accepting the glass. It's a good 50 hours worth of work if you have fiberglass experience..... if not you might want to double that.

 

I'd buy a spare set of bags to do the mod with so you'll always have your stock bags to put back if you ever need to.

 

I'd be more that happy to walk you thru the process if you decide to do it.

 

Bob

 

Thanks for the info Bob.

Your bags look amazing

 

I was more of thinking widening the bags using ABS instead of fiberglass but have not looked into if it is possible to use ABS. Will consult with the ABS workshop here in my town on the matter.The fiberglass is of cause an option and I do have a extra set of unharmed bags so I am pretty much all set up for the task.

Think I will take this as a next winter project and will take you up on your guidance when the time comes. Thanks so much for your offer of help - highly appreciated

[coop]

Thanks for the info Bob.

Your bags look amazing

 

I was more of thinking widening the bags using ABS instead of fiberglass but have not looked into if it is possible to use ABS. Will consult with the ABS workshop here in my town on the matter.The fiberglass is of cause an option and I do have a extra set of unharmed bags so I am pretty much all set up for the task.

Think I will take this as a next winter project and will take you up on your guidance when the time comes. Thanks so much for your offer of help - highly appreciated

 

Thanks Jonas.. I never worked with ABS other than a repair using Norton Speedgrip.

I've always found ABS difficult to sand / prep for paint. I'd be interested in what your shop has to offer. Please keep me posted. Have a great day!

Bob

[muaymendez1]

Hey Jonas,

 

Nice job on the box.... very neat and looks great with the extra lights.

 

We were working on the same thing this weekend but I was going the other way.

 

I put a different laydown, curved license plate holder on the bike and had to cut and solder all of the joints in there to cram everything in even a smaller triangle ) And went with smaller lights ) Oh boy...now everyone can see when lI last had my bike inspected 07!

 

Bob

 

Hey that's a Jersey plate hello from rahway

[coop]

Hey Bro,

 

I'm up north in west milford but down in your area all the time... Covanta, Philips 66, Linden Cogen. Never on the scooter down there though.