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Expedition 134 top case storage box for rear rack

dmonkey

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Inspired by @Clancy oto 's setup, I wanted to give the Expedition 134 heavy duty storage box a try. It's 55L, has a weather-proof seal, is lockable, and is supposed to hold up well to UV. I purchased it through Das Mule in the USA.
Like many of the crate setups it could use a stronger base to anchor rather than just a few fender washers stretching the plastic, so I cut a sheet of aluminum composite to make a light but sturdy inner floor support.

To start I traced a template of the box on cardboard, lined that up on the rack and found that it hangs over just 2 inches on each side when centered. I then used a sheet of paper to trace out the holes for bolting it to a rack, just by poking a pen through the paper at each hole. The aluminum composite sheet is very easy to cut using hand tools. I traced the shape to it, used a yard stick to get a straight line and ran a utility knife down the line to score the surface, repeated that a few times, and then bent the sheet and it snapped at the line. I used a file to clean up the edges. With the holes traced I drilled holes through the box and the aluminum composite sheet. For some extra anchoring on top of the M6 bolt holes, I used two of the rack bolt holes with spacers inserted between the rack and the Expedition 134 box. On top of the rack I put a sheet of toolbox liner cut to stick out slightly from under the box, on top of the toolbox liner I put some fender washers (best to do all this with the bike on the center stand and level so you're not fighting gravity keeping them in place while mounting the box), then the box, then inside the box is the aluminum composite sheet for floor support, then another set of fender washers, then the bolts, and finally another sheet of toolbox mat to protect cargo from getting scratched up on the bolt heads. The liner mat on top of the rack is necessary to prevent noise of the box bouncing around on the rack, with it installed that sound is gone and I don't know if the box is even bouncing around anymore since it's sitting on a compressed mat that might have eliminated that issue entirely rather than just the sound of it.

The Expedition 134 box weighs about 8.84 lb and the sheet of aluminum composite weighed 1.7 lb.
For a weight comparison the Givi 58L Monokey Top Case with an interior cargo net, interior foam floor pad, and backrest weighs 15.54 lb. This weight includes the integrated lock mechanism, but doesn't include the weight of a Givi mounting plate. I will likely stick with the Expedition 134 on this bike because its 55L is more usable in shape than the 58L of the Givi setup, it's nice to not have to unlock the case every time you want to open and close it as is necessary on the Givi, it's quite a bit lighter, and I like the aesthetic better as well. ROK Straps or cargo net anchors both fit the top of the Expedition 134 well and depending on what I'm hauling and where I'm going I'll throw a padlock on the box to lock it. I'm able to fit two full face helmets in the Expedition 134 case easily, while it was tight for the Givi 58L. For 8-packs of cans it fits three wide and two tall for a total of six before you're strapping some on top, or adding a layer and using some straps to hold the lid down against them without it fully closing. With the box mounted flush with the rear of the rack I can still use it as a back rest while leaning back, though not as comfortable as the back rest on the Givi it is at least easier to avoid contact with it when you don't want to be up against it (over bumpy terrain), and there's room to pack some items in front of the box for a better back rest or lumbar support.

expedition1.jpgexpedition2.jpgexpedition3.jpgexpedition4.jpgexpedition5.jpgexpedition6.jpgexpedition7.jpgexpedition8.jpgexpedition9.jpgexpedition10.jpg
 
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dmonkey

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If you wait to install the lid on the Expedition 134 case until after you've got everything measured, drilled, and ready for mounting - it will make it a bit easier. With the case unmounted, empty, and the lid open it's easy to tip it over toward the hinge side. Just make sure if you're installing it without the lid that the hinge is facing the direction that you want it. I think they recommend that once you install the lid you let it stay closed for a day or two to form a good initial seal.
 

dmonkey

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I attached a "Givi E161" net meant for a Givi Outback 58 Liter Top Case to the inside of the Expedition 134 lid. Drilled 4 holes through the inner lid support ribbing and ran zip-ties through them to attach the net. It is stretched more widthwise than heightwise, but it fits alright. Too much weight may damage the lid or its hinges over time, especially when held in the open position, so I only plan on using this to hold light items. Paper documents/maps, stickers or postcards picked up while touring that I don't want to bend, snacks, some spare paracord, those types of light items.

lid_net (2).jpg


lid_net (1).jpg
 

SneakyDingo

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I bet it can take much more than that, but treating it well will give it longevity. I'd be surprised if it couldn't hold two bicycle water bottles (like the Camelbak Podium ones). That'd be about 3 lbs.
 

Getyourown

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Jan 1, 2023
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Getting ready to do this installation and I need to turn to hardware store for the mounting bolts. Do you remember the lengths of the m6 bolts and the rack mounting bolts you purchased?
 

dmonkey

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The 4x M6 bolts I used are 30mm long, the 2x M8 bolts that replace the OEM rack attachment bolts are 65mm long, and I have a Japanese market rear carrier on the CT now that added two more threaded holes where I'm using M8 bolts that are 45mm long. These lengths work with a layer of Harbor Freight toolbox drawer liner between the rear carrier and the Expedition top case to prevent scuffing the rear carrier, a sheet of aluminum composite inside the top case to add some rigidity to the inner floor for the fastener tension to be distributed on, and some fender washers to also help with distributing that tension. The lengths would likely still work with some of those components missing or swapped out.
 
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