3D Printed Extended Toolbox

[Dohz]

I made an extended version of the stock toolbox and is long enough to fit a 19mm stubby HF wrench(see below). It reuses the stock lid, pin, and hardware.

This post keeps disappearing so I'll exclude the STL file for the time being.
I uploaded the STL here instead: https://www.thingiverse.com/thing:7367722

http://imgur.com/9TG2Y7e

http://imgur.com/7rq4MTC

http://imgur.com/895LDs3

Beefed up the sidewalls and loosened some tolerances:

http://imgur.com/bDOaWyR

 

[BergyPatty37]

Looks awesome! Have you thought about making it wider and thicker or did you just extend so you could reuse the factory lid?

 

[Dohz]

Looks awesome! Have you thought about making it wider and thicker or did you just extend so you could reuse the factory lid?

I have thought about both and may do that for a future version. I wanted to keep this version minimal and still compatible with side racks, but just long enough for some wrenches.

I may do a V2 that has increased dimensions but I want to be cautious not to increase the moment arm to be too large. I'll feel it out based on how this one holds up.

 

[BergyPatty37]

Yeah I would agree not wanting to overload it if too big. What do you plan on carrying in the box now that you have a little more length?

 

[Dohz]

At the very least a tire kit.

Probably something like:
19mm wrench
14mm wrench
Tire irons
Patch kit
Pump

Still putting together my toolkit, so we'll see.

 

[Dohz]

Working on a larger version w/ lock.

http://imgur.com/2DL8Lhm

http://imgur.com/SkivAih

http://imgur.com/4YHkIGY

http://imgur.com/CTLutgm

 

[BergyPatty37]

@Dohz Looks sweet. Would you put a rubber gasket on it to waterproof it better?
And how much weight do you think something like that would realistically be able to support?

 

[Dohz]

@Dohz Looks sweet. Would you put a rubber gasket on it to waterproof it better?
And how much weight do you think something like that would realistically be able to support?

Yes to the gasket. I have been brainstorming ways of waterproofing. I found some pool filter O-Rings that are readily available with a diameter of around 5.5"- 6" that would work well. I am also thinking about making a gasket mold that you could screw a tube of RTV into, or use a 2 part silicone. There's also the option of cutting out the gasket from a sheet of Neoprene or Silicone and designing an undercut for the gasket to slide into.

Weight? Really not sure. Injection molded parts are going to be way stronger than 3d printed parts, so I have compensated for that with thicker walls. Currently the shell is at 8mm thick, but the biggest limiting factor is going to be the top rib that mounts to the frame. I have it at a thickness of 4.3mm which is limited by the spacing on the stock bolt, but I am planning to add ribs reinforcing against lateral forces. At a certain point the weakest link is going to be the welded support bracket itself which can't handle very much side to side force. So I was also thinking about making a crossbar that connects to another bolt, maybe the one connecting the rear taillight assembly.

My goal is for at least a few pounds of load capacity comparable to other toolboxes I've seen. I'll probably use CF-Nylon 6 or CF-Nylon 12, both pretty durable.