SneakyDingo
Well-known member
- Joined
- Aug 6, 2021
- Messages
- 1,573
DISCLAIMER: This is prototype level work. Copy at your own risk.
First off, my idea: An Apache 4800 case mounted to a Packout base.
Why would you even do such a thing?!
Other options
I looked at a few existing options and didn't like any of them.
Apache 4800 case = Stealthmounts Packout feet + 1/8 in. ACM Black to hold everything together, mounted together with the appropriate fasteners, washers and whatnot. Because the Packout system doesn't have an aftermarket locking pin to prevent the case from ejecting, I 3D printed one.
How much did it cost?
**mumbles** ok ok, it cost $171.41, with around $54 of decisions that increased the cost in the name of reliability and repeatability. This includes "leftover" stuff, like I still have most of a roll of double sided tape, etc. right down to the bolts. There were a few places I could have cut costs, but I went for a little more premium because I felt the extra cost was worth it.
What was the biggest design problem?
The biggest problem, by far, is that no aftermarket option exists for the locking pin for the packout to prevent it from ejecting while in motion. This really is two problems: how do you stop it ejecting, and how do you prevent it stealth ejecting without you realizing it. Because of this I mounted it so it ejects towards the rider so I have a better chance of feeling it eject, and I designed a locking pin prototype.
This v1 was largely for fit: in order to mount the stealth feet on to the case, everything needed to be in the position it would be when the case was secured. So I put everything in place very carefully, mounted it with double sided tape, screwed the feet on and then everything went to sh*t when something shifted slightly. v2 of this is currently on the printer so I can get out there and use the case before coming up with v3.
I 3D printed a slim magnetic insert for the Packout plate that sits flush with the ACM, and then printed a pin and bracket that goes through. They're held together by 6 magnets, which provides plenty of force. Being mindful of the fact that this pin only serves to stop the case from sliding forward so it isn't subject to too much force, 3D printing has specific limitations that need to be worked around for a project like this (such as layer orientation and changing settings to reinforce stress points). This step was also to test it was strong enough, wouldn't eject randomly because it was too weak for the application or because the magnets didn't provide enough holding force, and to make sure everything was in just the right place before the Stealthmounts feet were screwed into the cas.
v3 will use the learnings I have from actually using it and will start to be similar to what the actual Packout mount retention looks like, with an enclosure around a sliding mechanism. However unlike their system, I'll be using one with magnets to lock it into the two positions instead of whatever they're using (probably a spring), because it is substantially cheaper to produce and far easier to arbitrarily position (magnets cost around 8c each when purchased in bulk, and I use them in a variety of other projects so I buy in bulk).
How reliable is it?
The ACM and packout plate seems reliable. The 3D printed part is frequently looked at (since I use it on the thing I take with me every time I leave the bike), so it'll be checked for damage.
In the event of an in-flight failure of the 3D printed part, the packout feet allow the case to be mounted forward or backwards. The case can be turned around and secured using zip ties around the handle.
The profile of the magnetic part flush with the bottom of the packout crate
What the pin looks like when pushed through the packout plate. It's worth noting as an injection molded piece, there's always a draft angle on the packout plate, so nothing is directly up and down. This has just enough clearance to pass through the tight spot.
v1 of the mount.
First off, my idea: An Apache 4800 case mounted to a Packout base.
Why would you even do such a thing?!
- I wanted a waterproofed enclosed case for light duty hauling that I could take with me and I didn't want it to look like a toolbox.
- I wanted to be able to put a crate on the back if I wanted to, because I do use the crate for crate things quite a lot.
- I wanted to be able to remove either of those easily because it interferes with the dog in my backpack.
- I wanted to have something with good tie down anchor options. I have some other other luggage that can fit on the back (40L duffel bag).
- I wanted to be able to easily pop off the storage and take it with me. When loading up the milk crate, I wanted to be able to unlatch it, pop the whole thing off and just carry that inside instead of fiddling around like I currently do. The same applies to the enclosed case - unlatch it quickly and bring it with me, both to deter theft as well as I see me using it a LOT during the cold, wet months.
Other options
I looked at a few existing options and didn't like any of them.
- Givi has a mounting plate and a top box, which sets you back around $230 for one of their smaller options. I didn't like this option for a variety of reasons, but it was the highest quality.
- There's a Shad case plus universal plate, which is much more affordable at around $140. I hate the look of that, but that definitely was my top contender for price.
Apache 4800 case = Stealthmounts Packout feet + 1/8 in. ACM Black to hold everything together, mounted together with the appropriate fasteners, washers and whatnot. Because the Packout system doesn't have an aftermarket locking pin to prevent the case from ejecting, I 3D printed one.
How much did it cost?
**mumbles** ok ok, it cost $171.41, with around $54 of decisions that increased the cost in the name of reliability and repeatability. This includes "leftover" stuff, like I still have most of a roll of double sided tape, etc. right down to the bolts. There were a few places I could have cut costs, but I went for a little more premium because I felt the extra cost was worth it.
- Instead of zip ties I used ACM, increasing the cost by $31.29
- Instead of cheaper feet I didn't trust (+$12) or 3D printing the feet (+$21.95), I went a more premium option for the feet. It's worth noting that in the prototyping stage, I did 3D print some Milwaukee packout feet because I wanted to see if it would even work before dropping money on ABS molded option.
What was the biggest design problem?
The biggest problem, by far, is that no aftermarket option exists for the locking pin for the packout to prevent it from ejecting while in motion. This really is two problems: how do you stop it ejecting, and how do you prevent it stealth ejecting without you realizing it. Because of this I mounted it so it ejects towards the rider so I have a better chance of feeling it eject, and I designed a locking pin prototype.
This v1 was largely for fit: in order to mount the stealth feet on to the case, everything needed to be in the position it would be when the case was secured. So I put everything in place very carefully, mounted it with double sided tape, screwed the feet on and then everything went to sh*t when something shifted slightly. v2 of this is currently on the printer so I can get out there and use the case before coming up with v3.
I 3D printed a slim magnetic insert for the Packout plate that sits flush with the ACM, and then printed a pin and bracket that goes through. They're held together by 6 magnets, which provides plenty of force. Being mindful of the fact that this pin only serves to stop the case from sliding forward so it isn't subject to too much force, 3D printing has specific limitations that need to be worked around for a project like this (such as layer orientation and changing settings to reinforce stress points). This step was also to test it was strong enough, wouldn't eject randomly because it was too weak for the application or because the magnets didn't provide enough holding force, and to make sure everything was in just the right place before the Stealthmounts feet were screwed into the cas.
v3 will use the learnings I have from actually using it and will start to be similar to what the actual Packout mount retention looks like, with an enclosure around a sliding mechanism. However unlike their system, I'll be using one with magnets to lock it into the two positions instead of whatever they're using (probably a spring), because it is substantially cheaper to produce and far easier to arbitrarily position (magnets cost around 8c each when purchased in bulk, and I use them in a variety of other projects so I buy in bulk).
How reliable is it?
The ACM and packout plate seems reliable. The 3D printed part is frequently looked at (since I use it on the thing I take with me every time I leave the bike), so it'll be checked for damage.
In the event of an in-flight failure of the 3D printed part, the packout feet allow the case to be mounted forward or backwards. The case can be turned around and secured using zip ties around the handle.
The profile of the magnetic part flush with the bottom of the packout crate
What the pin looks like when pushed through the packout plate. It's worth noting as an injection molded piece, there's always a draft angle on the packout plate, so nothing is directly up and down. This has just enough clearance to pass through the tight spot.
v1 of the mount.
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