Givi Monokey side case project

Monstard · Sep 30, 2014

i've been meaning to get the Givi E22 side case to replace the bulky oem bags but didn't quite know if it will look right on the hyperstrada. having seen a member's (peoples1234) photo of an E22 case mounted on his bike, i finally decided to give it a go

the advantages of the E22 over the oem, for my purposes are:

- narrower, city driving/filtering
- better locking system
- waterproof shell (doesn't need an inner liner)
- easier to mount/dismount
- top lid opening

but instead of getting the ducati bellevue bracket (too rich for me), i decided to design my own as i have access to some T6 aluminum plate, 10mm thick. i very much appreciate the assistance of peoples1234 for providing me some measurements crucial to the design

first off, i had to design the bracket. this bracket should be able to accommodate the E22 as well as the rotopax fuel pack system i have on order. here's the design on a piece of corrugated cardboard

i sent the cardboard template to a local fabricator to have it laser cut in acrylic. the acrylic template will be used for test fitting and since it is transparent, it would be easier to locate and mark the mounting holes

i mounted the template and saw it a little too high and too far back

so i relocated the holes and made some slight adjustments on the design. here's the template with some measurements and notes for the aluminum fabricator as reference

now i'm off to the fabricator for waterjet cutting. will be posting again soon as there's progress on this project

gatdammit · Oct 1, 2014

Nice fab work. You should punch out a couple sets and sell them. If I ditch OEM, I'm pretty sure I want the E22's.

And don't lose that template!!!

Monstard · Oct 2, 2014

thanks, gatdammit. i don't know about making more and selling. i can keep the fabrication cost low for personal use because i got the aluminum plate for free from the scrap yard of a ship repair facility. and they don't come up with a piece of scrap big enough for this purpose that often. had to spend some time digging around the yard

Update:

the aluminum fabricator is busy with several jobs on their schedule so i had get in line for the waterjet cut. it may take a few days before they can entertain my job request. meanwhile, i'll try to make a list of the other hardware needed, some had to be imported, some purchased locally and some had to be fabricated. more later...

Monstard · Oct 3, 2014

Parts/hardware List

to mount the aluminum plates to bike bracket: (length of all M6 bolts are measured in mm, excluding the 5mm head)

2ea M6x40mm
2ea M6x35mm
2ea M6x30mm
6ea flat washers

6ea stainless steel spacers (these were fabricated out of a length of 15mm diameter SS rod and drilled in the middle with a 6mm hole to accept the M6 bolts):
2ea 15x10mm
2ea 15x15mm
2ea 15x20mm

Givi hardware to accept the monokey system (ordered online, still shipping)

2ea Z124 attachment clamp

2 sets Z125 mushroom spacers

2 sets Z126 rubber buffers

other parts not included in the Givi kit, to mount the Givi hardware to the plate

4ea M6x30mm countersunk
4ea locknuts
8ea flat washers
4ea M6x25mm

Monstard · Oct 10, 2014

waterjet cutting the aluminum plate is taking longer than expected. the fabricator has "priority jobs" on queue and the givi monokey hardware is on back order (2-3 weeks). it's the middle of the wet season here and i badly needed to install the E22 cases for when i go to work. so i got the givi E251 universal plate as a temporary solution

i did need a dremel to make the mounting holes line up with the oem bracket. what i like about this is that 99% of the side case mass is forward of the rear axle. but this "best position" is a little bit too high for my taste. swinging a leg over when mounting could pose a challenge for short legs like myself. the aluminum plate i designed allows the cases to hang least 2 or 3 cms lower

zippy49 · Oct 29, 2014

A very nice job, Monstard. Could you post some overall dimensions from your template? The pic is a bit too blurry to make the others out. I think I could make a fully dimensioned drawing.

Your setup seems to have plenty of clearance to even the stock muffler. I especially like the extra passenger heel clearance, which was a deal breaker with the wifey when we tried Nate's bike, with his big Givi on the Bellevue mount. If this works out, maybe she'll let me sell the Harley...

gatdammit · Oct 29, 2014

Might require a shroud to protect the right case but clearance looks good. This will be my upgrade when the stockers are toast.

Monstard · Oct 31, 2014

i haven't moved forward with this project yet. my job request for aluminum cutting is still on queue. so i'm still stuck with the temporary fix of using the givi plates to mount the cases. they seem solid enough and held on after a couple of weeks use

zippy49 said:
A very nice job, Monstard. Could you post some overall dimensions from your template? The pic is a bit too blurry to make the others out. I think I could make a fully dimensioned drawing.

Your setup seems to have plenty of clearance to even the stock muffler. I especially like the extra passenger heel clearance, which was a deal breaker with the wifey when we tried Nate's bike, with his big Givi on the Bellevue mount. If this works out, maybe she'll let me sell the Harley...

thanks, zippy. even with my set-up, i think heel clearance will still be an issue if i use the bigger 33-liter givi cases

for the dimensions of the plate, basically i patterned it after the rotopax can measurements as that was the original plan. double duty as mount for monokey cases was just an afterthought after i saw peoples pics

width: 355mm
height: 242mm
x-arms: 20mm
diagonal mounting holes center to center: 175mm
horizontal holes for countersunk bolt sleeves: 227mm

Monstard · Oct 31, 2014

gatdammit said:
Might require a shroud to protect the right case but clearance looks good. This will be my upgrade when the stockers are toast.

i reinstalled the stock exhaust in prep for a trip. the scp crt gives me migraine after a long drive. there's at least a centimeter of clearance between the givi plate and the exhaust. no need for a heatshield. even with the scp crt where exhaust gas blows to the case in standing traffic, the plastic just gets warm and no cause for concern. without the cases, the bike won't win any beauty contest so it's best to just leave them on

zippy49 · Oct 31, 2014

Monstard said:
without the cases, the bike won't win any beauty contest so it's best to just leave them on

Wow you are right about that! Reminds me of the infamous milk crate bolted to the rear rack. But thanks for the pics, Monstard.

gatdammit · Nov 1, 2014

Plenty of clearance. So, is trying to adapt stock mounts totally out of the question?

Monstard · Nov 2, 2014

gatdammit said:
Plenty of clearance. So, is trying to adapt stock mounts totally out of the question?

no, i don't think so. i've actually toyed on the idea of transferring the plastic mounts/hooks from the oem bags to the e22 cases. with enough reinforcing plates to make sure the case won't crack from where the mounts are bolted through, i think it's doable. but i don't like the protruding nuts and bolts inside the case so i decided against it

Monstard · Nov 6, 2014

plates have arrived

now i can proceed with the project... they're somewhat heavier than i expected. i might have to remove some material later in order to reduce the weight. perhaps i can cut off the vertical sides as i feel i over-engineered this thing, like it was built for a tank

next step is to clean up the plates then measure and mark the points where holes are to be drilled for the case attachment hardware (i.e. locking tabs and the bolt sleeves)

more photos later...

NurseDaddy · Nov 6, 2014

Forgive my quick and dirty Windows Paint work, kababayan! But you get the idea. Kinda looks like a tie fighter Star Wars thing.

gatdammit · Nov 6, 2014

They look too thick. But if the weight is kept in check, thick isn't so bad.

Monstard · Nov 6, 2014

NurseDaddy said:
Forgive my quick and dirty Windows Paint work, kababayan! But you get the idea. Kinda looks like a tie fighter Star Wars thing.

yep, it sure looks like it

i was hoping for it to look like the x-wing fighter but the angles are leaning more toward its dark side nemesis

gatdammit said:
They look too thick. But if the weight is kept in check, thick isn't so bad.

the thickness is the same as the ducati bellevue plate (10mm) and same spec (T6 alum) as well, feels really solid. but my design has more material so its heavier. considering that each plate will carry no more than 6 kgs, i'm now more inclined to the tie-fighter look of nursedaddy to cut on weight. i found i over-built this thing so off it goes again to the fabricator but i was assured i'll get it back today

arif · Nov 7, 2014

Hi Monstard

Thank you for your generosity in sharing the details of your design. I live in Australia and even if bellevue were willing to post to Australia i would not be able to afford it.

When i saw your temporary solution i thought that would suit me as an ongoing solution.

Do you think they will stand up to long term use? i dont have a problem with their look as i will take the whole bracket off if i am going to take the case off.

Thanks again

Monstard · Nov 7, 2014

arif said:
Hi Monstard

<... snip>
Do you think they will stand up to long term use? i dont have a problem with their look as i will take the whole bracket off if i am going to take the case off.

Thanks again

hmmm... i used the temporary plate for only barely a month so i can't say anything about long term use. i can only tell you that the givi plate felt solid when they were installed. it felt like you can almost lift the whole bike by just hooking onto the plates. the givi E22 cases are spec'd for not more than 120 km/hr but i've tested the whole system at 150 kph and it didn't budge

arif · Nov 7, 2014

Good enough for me

Thanks

Monstard · Nov 8, 2014

update

i had the vertical sides cut and what a significant weight reduction it made. i also assembled the hardware and mounted everything on the bike

still not pretty but it looks better, imo. i'll call this the tie-plate adapter. next step is a test ride then have the thing black anodized

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