Wooden top box

[Rusty Bucket]

Incredible job.. ...can I ask how heavy it is?

[Barbarossa]

Hi Rusty,  the box is made from 6mm tricoya mdf,
      ( totally waterproof )  and weighs 2.94 kg/ 6.48 pounds. The paint and lightweight campervan carpet
lining the inside probably adds a further pound or so.
I was surprised to find that a 47 litre givi weighs
9.72 pounds and has a max loading limit of 22 pounds.  That's not much !!!

[Ace50]

How do you join and finish the corners of the box on the tricoya?

[Barbarossa]

Hi Ace,  Cut the six sided base first,  I used 9mm marine ply, and fix it to your rack.  Cut a
Cardboard template that will be one side of the box ,put a vertical fold in it, and hold it against the base with a few veneer pins,  start to trim it with scissors until it starts to flow with the lines of the bike. Use the template to mark out the two pieces that will make one side, make two more pieces that will be a mirror image for the opposite side.  Plane a bevel (mitre) on all edges  roughly 22 degrees or more accurately ( one half of the predicted angle of the finished joint. Pin and glue each pair of side pieces to the ply base and pull the vertical joint together with masking tape. Keep adding pieces until you have a complete shell which will be sawn through with a fine handsaw later to separate it into a top and a bottom. All joints can be held with masking tape until the (waterproof)  glue has set, this takes longer than normal because the tricoya won't absorb the water in the glue. When done strip off all the masking tape and with a sandpaper block rub along each joint until  you have a regular pencil round everywhere,  about 3mm radius, finish with a fine flexible sanding block. When you cut the shell into two halves you can re- enforce the joints on the inside with fibreglass and ribbon, although this isn't strictly necessary.
Good luck

[100milesaway]

 That looks absolutely fantastic, great work and well done.  However, I have wooden top box coming soon enough, thanks to my health issues. 

[TYKE]

Originally Posted by 100milesaway

That looks absolutely fantastic, great work and well done.  However, I have wooden top box coming soon enough, thanks to my health issues. 

    Ya daft bugger     

It'd better not be that soon.....it's your turn to buy Bacon and egg butties         

[100milesaway]

Originally Posted by TYKE

   Ya daft bugger     

It'd better not be that soon.....it's your turn to buy Bacon and egg butties      

Best hurry up then Rog. Winter is well on it's way.   

[Barbarossa]

Hi Versys God,  many thanks for your very flattering comments.  I really do hope that your allusion to an impending wooden structure of your own was greatly exaggerated . Truly I do. Take care Bud.
                               Nick Gwyther.  London

[100milesaway]

Originally Posted by Barbarossa

Hi Versys God,  many thanks for your very flattering comments.  I really do hope that your allusion to an impending wooden structure of your own was greatly exaggerated . Truly I do. Take care Bud.
                               Nick Gwyther.  London

I'm fine thank you Nick. I have lots of issues, however I should be good for a few thousand miles yet. Ever onward.