Storage Box Mounting Bracket
An ergonomically designed replacement mounting bracket for a rear storage box on a motorcycle that allows riding passengers to sit more comfortably in a reclined position.
problem
Wendy’s back hurts because the rear storage box doesn’t let her naturally sit while riding on road trips with her husband.
The storage box mounted behind Wendy’s seat is tilted too far forward and prevents Wendy from sitting in a regular, comfortable riding position. Leaning this far forward strains Wendy’s back muscles and pushes her too close to her husband’s back. Riding like this reduces Wendy’s visibility so she can’t enjoy the scenery, and if her husband suddenly hits the brakes, her helmet knocks against his.
Hi, I’m Wendy. “I like taking road trips with my husband on our motorcycle, but I can’t ride for long because my back starts to hurt.”
Solution
A new ergonomic mounting bracket that changes the angle of the storage box and allows Wendy to lean back and relax. It functions the same as the original hardware; the box can still be removed and attached as securely as before.
box mounting process
Securing the storage box to the luggage rack with the new bracket is the same as before.
“The bracket that Paul created has made a huge difference for me. Now, I can ride eight or nine hours without any back pain at all.” - Wendy
prototype process
To create each prototype, I used Rhino 6 to model the design and contracted with a local water jet machine shop to cut the parts. After receiving the pieces, I bent, assembled, and welded them together. I installed and test fit each prototype and marked them with design changes. When there were no more changes, I had the final prototype powder coated.
Proof of concept
Assembling something quickly and simply is a great way to solidify an idea and prove that the concept solves the problem. While speaking with Wendy and beginning to understand the problem she was having, I used what I could find to fashion a wedge that would lean the storage box back. A cookie tin fastened with duct tape gave us the right angle for Wendy to be comfortable.
Prototype 1
The original hardware gave me an idea of the size and layout of the first template. I traced and scanned the original hardware to create a general outline and measured the holes and angles precisely with calipers to ensure the prototype would fit correctly. The first prototype, as well as the others, fit and functionally worked. It traveled 3500 miles to northern Alaska and back while later prototypes were in development.
Prototype 2
The second prototype aimed to solve the problems of the first. Instead of using the original hardware in combination with my bracket, it would need to replace the original hardware. The customer would be able to swap out one part for the other instead of needing to modify their original hardware and combine it with the new bracket.
Prototype 3
The changes made to the third prototype refined the design and decreased assembly and installation time. The most visible change, the logo, was added to the cut file instead of needing to be welded on as a separate piece.
Prototype 4
All of the manufacturing kinks had been worked out in the previous attempts. A few design changes needed adjusting from the third prototype, but nothing that would create a fitting issue.
template design changes
The images below depict the cut files of each prototype and how they changed as I developed the design.
This bracket was designed for the BMW R 1250 GS Adventure but will also fit the R 1250 GS model. It replaces the BMW OEM Aluminum Top Case mounting hardware and attaches to the BMW Luggage Rack.
