Milwaukee Packout - how are you mounting it to the rack?

[SneakyDingo]

Topic says it all. The holes don't line up with the rack mounted holes so... is there something more permanent than zip ties that I'm missing?

 

[Equal]

I just drilled holes though the packout. Used the two wider threaded ones that come on the bike. The other is just through the angled slot holes in the rack to a large washer and nut, I also put some gorilla tape on the washer to prevent damaging the paint on the rack

I had it too close initially, hence the bits of gorilla tape. I found having it next to the handle behind the seat too close and annoying especially off road. I have about 4" of space between the box and the handle behind the seat and no issues.

Don't tighten very much and use blue threadlocker.

 

[op46]

I put base plate on with 5 industrial grade zip ties and then snap the various boxes and bags to it.

 

[SneakyDingo]

Yeah, you were who I was thinking of @op46, couldn't remember what the username was though. I saw someone on Youtube who mounted his with what appears to be 1/4" ply but that doesn't feel like it's something I'd want to do in the wet climate we have here.

The winning approach here might be iterative design. Use zip ties short term, and after learning a bit, use something else more long term.

 

[Harv]

180lb zip ties at Harbor Freight - $1.79/10. Best 2 bucks you will ever spend. The zip ties have zero clearance issues as far as attaching stuff to the mounting plate. You could easily pick up the rear end of the bike by the mounting plate if it didn't flex.
I have the long saddle so about 5" of the actual box overhangs the back. 2/3 of the plate is over the bike rack so plenty stable. (I am a large human so no chance of a wheelie.) I'm sure we're all sticking to the 44lb limit on the rear rack so should be fine.

 

[SneakyDingo]

@Harv, most other people mount it per safety specs, but you have yours mounted exactly the way I want to mount mine. Any trouble with it dislodging, or is the retaining clip enough to keep it in place?

 

[Harv]

@Harv, most other people mount it per safety specs, but you have yours mounted exactly the way I want to mount mine. Any trouble with it dislodging, or is the retaining clip enough to keep it in place?

The way the attachments fit into that base plate is what breaks this system out from the rest. Even IF the clip failed, the pack would have to slide back and jump out of the pockets. I'm not saying it can't happen but I'd like to see what the genius was doing that made it break loose. The box coming off would be the least of his problems.
I'll have to get a picture of me and a friend lifting the rear end up by whatever box I have mounted. If someone doesn't think four 180lb zip ties is enough they can look at my pics and find at least four more points to tie to.
The only weakness in these systems is that the release mechanism doesn't lock. Unless you have it cable-locked to the bike, it could just walk off. I have a fix for this that I'll post after I install it on mine.

 

[dmonkey]

Plastics do deteriorate with sun exposure, so best to check them over time and replace as needed. I've even had the heavy duty UV ones become brittle on bicycles after a year or so in the sun. Stainless steel ties are a good alternative, just have to mitigate them scratching any surfaces if you care about that.

 

[Harv]

If I was taking an extreme trip where I knew the case was not coming off of the bike, I would get a pair of u-bolts like this, bend the top back about 45 degrees so it fit behind the aluminum bar on the corner of the case, run the legs down through the holes on the base and cinch it. I'd mount the pair of u-bolts on opposite corners and call it good.

 

[akirk626]

i just used 4 M10 bolts with an allen head insert and the four threaded holes already on the rack. That way i can use the allen key that came with the bike under the seat to remove and install quickly when needed. I also use a couple of bungee ties just to keep it from putting any extra stress on the four bolts considering they are in more of a straight line that in a four corners pattern.

 

[SneakyDingo]

Yah, m in sc has mentioned using aluminum ACM as a baseplate to spread the load a little.

I'm currently contemplating my ideas based on the equipment I have for cutting things, the baseplate, that I want to attach it more permanently than zip ties, etc... right now I'm leaning towards some ACM in the right size as the intermediate connection between the packout plate and the Honda rear rack.