Mounting Givi Tool Box to PL2119CAM frames for Outback Panniers.

Super08

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Aug 6, 2017
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357
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AB, Canada
I wanted to see if I could get the tool box to mount to my frames instead of to the crash bars as Givi recommends and sells a mount for. I ordered the tool box and the universal mount for side frames.

Quickly mocking things up I found that there was only about 6.5" clearance from the highest point of the rear brake caliper to the bottom of the tool box if mounted as supplied. Yamaha lists the rear wheel travel at 7.5" so obviously if you hit something hard enough you would jam the brake caliper into the bottom of the tool box.

For my first attempt I made two small brackets to attach to the lower mounts to raise the whole mount by 1". The install went smooth as silk and everything fit pretty much perfect until I went to put the pannier back on. No go.... The mount is designed that it can only be mounted exactly as supplied to clear the Outback cases. The plastic mounts that align it with the sides of the frames now hit where the clamps were at the top of the mount on each side. As well The plastic cover and two of the screws were contacting the mounting bracket on the back of the pannier at the top.

I needed to go to plan "B"......
 

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Super08

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I removed my 1" extensions and remounted the tool box to ensure the pannier would mount back to the frames OK which they did. So the position of the mount must stay as supplied to work. The tool box itself still had to be raised 1" to clear the caliper in the event of bottoming out the suspension. The way the box is made you cannot drill holes in the box other than the locations made for the holes. So sizing up the mount I checked to see if I could redrill the holes in the mount 1" higher without anything getting in the way. The lower 2 holes can be moved up 1" without issue but the top 2 holes would require the brackets I had previously made for the bottom of the mount as moving the box up 1" would put the holes up in empty space.

I redrilled the lower two holes and test fit everything on the bike using just the lower two mounting holes to the tool box just to check fitment. Everything went on perfect including the pannier. I took it all back off again to put the 1" brackets on the top mounts.

This is where I run into problems again. The tool box is designed in a way that there is only about 1/16" of clearance between it and the mount. That leaves no room to put a normal bolt or nut to attach the mount extensions. I went in my hobby room to see what I could come up with. (I fly RC planes and have a very extensive stock of hardware) What I came up with was to use two M5 blind nuts (T nuts) as that was the only thing that would fit in such a thin space. I had to snap off the teeth on them that are intended to dig into wood to stop them from turning first. Then insert them into the back of the mount and then use a bolt and washer that was the correct length to go just through the blind nuts and then grind the M5 bolt off flush with the back of the blind nut when tight. I put it all together again and put it back on the bike. Everything fit and the tool box was positioned exactly where I had it when I first tried moving the whole mount up.
 

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Super08

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Checking with a tape going from the highest point on the caliper which was the rubber cap on the bleed screw I had 7 and 9/16" of room. There is lots of room to get a key into the lock and remove the access door. I had to cut a small relief notch in the top tab of the door to allow room for the edge of the side frame mount.
 

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Super08

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The box when viewed from under the fender by the muffler looking across shows I only have about 1/8" clearance to the frame of the bike at the front of the box where it angles down. The top of the box at the rear just touches the side frame where I cut the notch in the door tab.
 

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Super08

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Here is the completed installation. I should also mention that I have about 1/2" or better clearance from the sidewall of the tire to the inside wall of the box. I have enough room for access that I can put my air pump with accessories in it's case into the tool box without taking anything out of the case.
 

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Hfjeff

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Sep 28, 2017
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125
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Central WI
Nice work! I just installed those same racks and am looking to add a toolbox so this is timely. Thanks for all the pics.
 

igipo

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Sep 29, 2016
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Bijeljina BiH
Followed your advice, lifted toolbox exactly 2.5cm (1inch). It can't go any further up, because it hits mounting point of PL2119 frames.
Thanks a lot, you saved me a lot of time!
::012:: ::012:: ::012::
 

npj1966

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Aug 17, 2014
Messages
141
Location
Fairfield County, CT, United States
Super08 said:
I removed my 1" extensions and remounted the tool box to ensure the pannier would mount back to the frames OK which they did. So the position of the mount must stay as supplied to work. The tool box itself still had to be raised 1" to clear the caliper in the event of bottoming out the suspension. The way the box is made you cannot drill holes in the box other than the locations made for the holes. So sizing up the mount I checked to see if I could redrill the holes in the mount 1" higher without anything getting in the way. The lower 2 holes can be moved up 1" without issue but the top 2 holes would require the brackets I had previously made for the bottom of the mount as moving the box up 1" would put the holes up in empty space.

I redrilled the lower two holes and test fit everything on the bike using just the lower two mounting holes to the tool box just to check fitment. Everything went on perfect including the pannier. I took it all back off again to put the 1" brackets on the top mounts.



This is where I run into problems again. The tool box is designed in a way that there is only about 1/16" of clearance between it and the mount. That leaves no room to put a normal bolt or nut to attach the mount extensions. I went in my hobby room to see what I could come up with. (I fly RC planes and have a very extensive stock of hardware) What I came up with was to use two M5 blind nuts (T nuts) as that was the only thing that would fit in such a thin space. I had to snap off the teeth on them that are intended to dig into wood to stop them from turning first. Then insert them into the back of the mount and then use a bolt and washer that was the correct length to go just through the blind nuts and then grind the M5 bolt off flush with the back of the blind nut when tight. I put it all together again and put it back on the bike. Everything fit and the tool box was positioned exactly where I had it when I first tried moving the whole mount up.
Super 8- Just found this post.... thanks for the write up

NPJ
 

Super08

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AB, Canada
Yes, then I bent the spikes down flat. I used metric M5 which is about the same size as 10-32 thread.
 

Super08

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Aug 6, 2017
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AB, Canada
Correct. I used a couple of washers under the bolt for spacing as well so I wouldn't have to grind down the threaded part of the blind nut. I cut the bolts to length so they didn't protrude out the back.
 

Super08

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To add to this thread someone else that followed this used rivets to attach the 1" extensions instead of T nuts and bolts.
 

ocgeek

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Aug 20, 2019
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95
Location
Italy
Hoping not to bother the thread this is the solution i ended up with
I decided to CAD design a plate which is hold by the 4 existing bolts (exchanged with longer versions) which are in the Givi frame (2x M6 at bottom , 2x M8 at top)
The plate i made is 3mm thick alu and has a double bending at the top (to go just behind the luggage retention and locking mechanism at top)

IMG_20200510_165029.jpg

IMG_20200510_140535.jpg

IMG_20200616_160937.jpg

IMG_20200616_161058.jpg

And here is the mounting of the plate (lucky me my measurements were dead spot on at the 10th of mm...)

IMG_20200617_184819.jpg

IMG_20200617_184826.jpg

IMG_20200617_185208.jpg

IMG_20200617_185230.jpg

Prepping the tool box after drilling it...
I have inserted 6x1mm nitrile o-rings as the standard mounting practice suggests; that shall keep water out of the drilled holes

IMG_20200617_191633.jpg


out

P.S. If anyone can benefit from the design here is the CAD file source for reusing
 

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