Join Date: Jun 2007
Location: Lawrenceville, PA, USA
Re: Helmet holder
UPS finally delivered around 6:30 so I was ready this morning with all parts and tools.
I bought some aluminum washers to use as spacers. I thought I might need two, but it appears that enough of the spacer extends through my aluminum bar such that I will have enough clearance with just one, although I may still need two to get the bars to sit level and not tilt along the slope of the plastic cover over the rear of the LT.
I drilled the large rear hole and confirmed it fit over the spacer with not much play. I then put a scribe through the front hole of the top case and with the rear hole over the spacer, swing the front to make an arc to locate the front holes and then drilled those. All went well and the bars fit over both spacers with very little slop. It may be a little trick to get this assembled with the bars and washers all being loose. If I had a TIG welder, I might try tacking the washers to the bars, but then the weld bead might interfere with the fit.
I then drilled two more holes to provide clearance for the bolt heads holding down the plastic cover, drilled and tapped the two 6 mm holes for the LidLox and then cut and filed the short legs to make them close to symmetrical. Finally, some sanding and cleanup and on to paint. Now just need to let the paint dry and see if I can get all of the parts to stay in place while I bolt it down. I am hoping the stock bolts are long enough with the additional space created by the washers.
Once I confirm fit, I think I will take some two-sided tape and stick the helmet holder bars to the plastic so that I can remove the top case without having to mess with the bars and washers.
2017 KLR650 "Mule"
2007 K1200LT "Starship Enterprise", VOICE II, Navigator V, Motorrad Communicator
1987 Kawasaki Voyager XII
1976 Kawasaki KH400
1973 Kawasaki 100 G5
1970 Rockford Chibi (the orange one)
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