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Discussion Starter #1 (Edited)
I guess it is time to finally jump in.

I started following this forum a little over a year ago. That led to checking nearby craigslists for used TW's. I got lucky and snagged a 2005 with only 216 miles on it. Since then, I have made a number of the usual modifications and tweaks discussed here and also have a few more planned. Thanks to all of you for your tips, instructions and suggestions.

I have owned lots of bikes, but this little guy quickly became part of my permanent collection.

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Brian
 

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Man a 2005 that still isn't broken in. That's a great looking bike. Congrats on the new bike.



Dan
 

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Must have more photos! Must have more photos! Please show us how you mounted the pelican box! And close up shot of the fuel bottles on the forks and how they are mounted. Man am I glad you finally came out!

Thanks in advance.

Happy new year.

Igofar
 

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Discussion Starter #4 (Edited)
Thanks guys.



Here are some details on how I mounted the fuel bottles. I used 3" Quick Fists - these are transportation grade rubber clamps that were originally designed to hold fire hose nozzles to the side of a fire truck. I bought mine on ebay. They hold a 1 liter fuel bottle very securely. I mounted the Quick Fists to pieces of flat aluminum stock 1.5" wide by 1/8" thick by 5" long. These were then mounted to the forks using the lower triple clamp bolts. This mounting provides clearance for the turn signals and also for the gas tank during full lock turns. See pics below:

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The Pelican case is mounted directly on top of the stock rubber pad on the rear fender using the 3 existing mounting locations. I used 6mm thread by 25mm long thumb screws with a rosette style knob for easy installation and removal. I ordered the thumb screws from McMaster-Carr. This mounting works fine for my needs as I don't carry a lot of weight in this case. If you want to carry heavier loads, you would probably want to beef up the rear fender/subframe.

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I then mounted two tool tubes to the sides of the Pelican case. The case that I happened to have was not quite long enough to allow mounting the tool tubes directly to the sides of the case. I had to make up a couple of aluminum mounting plates that I could first mount the tool tubes to and then mount these plates to the sides of the Pelican case. As many of you already know, these tool tubes hold a 1 liter fuel bottle perfectly.































Brian
 

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Great mods. You obviously have an appreciation for doing things with the "correct" fasteners. Sort of the opposite of the duct tape and wire tie type of person. Ride on. Tom
 

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Discussion Starter #9 (Edited)
Brian Where can someone get a case like that ? You do some nice looking work !!!!!!!!!!!!!!
Hi Rick,

Mine is a Pelican brand case. I have also seen similar cases under the Caribou brand. You can google either of these or check on ebay to find where you can buy one. I don't remember the exact model that mine is. The inside dimensions are approximately 15" long by 10.5" wide by 6" deep.

Brian

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I wouldn't want my gas in front of me in case of an accident. Let's say you crash on the asphalt and skid down the highway, the gas can either loses it's cap or gets a hole ground in the canister, you may be covered with gas, ready to ignite because of a hot exhaust. Instead of 2 quarts get a Clarke tank and gain about a gallon.
 

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You are indeed a very meticulous fellow. Those clamps are really neat and will likely be seen again on another bike. Super photos, sure to inspire others. Thanks, Gerry
 

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Armed and ready to launch! Welcome and thanks for sharing some great ideas, those Quick Fists are on my list for next summer. Actually I think I'll find a couple for the truck too.
 

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I wouldn't want my gas in front of me in case of an accident. Let's say you crash on the asphalt and skid down the highway, the gas can either loses it's cap or gets a hole ground in the canister, you may be covered with gas, ready to ignite because of a hot exhaust. Instead of 2 quarts get a Clarke tank and gain about a gallon.
The site would be a good place for a water bottle or a tool tube tho and moving the gas to the tubes on the rear. Admittedly they are not vertical but a well snugged cap should not leak or vibrate loose and besides you should top that tank as soon as you can create space in the oem tank. There are lots of thinks that can be mounted on those firemans mounts. Tom
 

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Fantastic post and pictures. I am curious about the copper pipe you have coming our of your exhaust--What purpose does it serve?? And as for inspiration, I will definitely be copying your front fuel mounting system.
 

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Discussion Starter #16
Fantastic post and pictures. I am curious about the copper pipe you have coming our of your exhaust--What purpose does it serve?? And as for inspiration, I will definitely be copying your front fuel mounting system.


Hi DCTW,



That is just a standard copper elbow that is pushed onto the exhaust tip. I have since painted it black to match the exhaust. I got the idea from someone else on this board. It does seem to redirect the exhaust noise somewhat so it is a little less annoying (also adds about 5 horsepower!).



Thanks for the comments,



Brian
 

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What's your rear tire? Looks like a Bighorn or Bighorn2.
 

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That copper piece is a 1/2" 45 degree bend, you can get them at any Home depot. I heard they were good for about 10 H.P. LOL
 

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That copper piece is a 1/2" 45 degree bend, you can get them at any Home depot. I heard they were good for about 10 H.P. LOL
I'm confused... I bought a 1/2" 45 degree bend copper piece and it was too small. It slid up inside of the stock exhaust with no grab. Are we sure it's not 3/4"?
 
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