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Tool Tray

By Dave Smith

Under Seat Storage Project


  This project is best suited to bikes without electric start. Ideal candidates are two-strokes that have siblings with electric start, like the KTM and Gas Gas lines.

Years ago, most offroad bikes came with tools and a place to keep them on the bike. Now, the rider has to work it out themselves. Rear fender tool bags are nice if the fender can support the weight, but make it tough for some riders to swing a leg over the bag. Front fender bags have the same support

requirements, but put the weight way in front, and interfere with score cards, headlights and WER dampers. Both types of fender bags put the tools "on display" for potential thieves. Fanny packs work well, but the rider ends up shouldering the burden. So, the project bike, a 2003 Gas Gas EC300, uses the area under the seat where the battery would be on the four-stroke model. The area holds a suprising amount of tools.


  First off, take a look for potential mounting points, possible interference with side plate(s), filter removal and wiring, and what shape would yield the most storage volume. In this image note the two screw gussets molded into the fender and the standing rib, mostly removed, to the right of the gussets. A simple vee shape would fit well in the area, be easy to fabricate and at first glance give enough room to store a decent sized tool wrap.


  Since there are a lot of different angles involved a disposible pattern made of very light gauge aluminum was to be used for test fitting. After making a few measurements a trial part was fabricated slightly over sized and bent to the shape desired.


  Trial fitting and trimming eventually yielded a part with these dimensions. Note that the mounting tabs changed quite a bit from the mock up to the final product. The notch on the left side is for the air filter access door.


  Here is the fabricated tray, less notch and mounting holes, before installation.


  The tray is mounted to the rear fender with two #14 screws and to the subframe with two hose clamps. The tips of the screws were ground off and the tabs that mount to the subframe were bent to match the curve of the tubing.


  The finished product gives a great place to store tools and doesn't interfere with simple things like air filter changes.

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