| Building GL1800 and GL1500 Travel bags |
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| Moderators: redbaron, MDKramer, Flyone, AZgl1500 | Page: 1 2   |
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| Posted: Mon May 3rd, 2010 12:38 pm | 1st Post |
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I will be showing how to make the Travel Bags with the GL1800 Bags & center filler panel only. Used 1/4" or 3/16" X 3" flat sheet for the braces mount. You will need to make the cut to match the bag shape. Drill & tap 2 holes each at 22 3/4" center to center. Install using the stock bolts that came with the bike. Using 2" X 2" x 1/8" square tubing drill the hole for the pin. I used a center punch the fit the hole in the hitch to line them up. Also drilled a 3/8" hole for the wiring to run inside the tubing. Don't have the length set as yet. Will be different between mount to Bike/Car or Trike. You will need to open the Trike Trunk to get you helmet out at least. You can weld the tubing on now being sure the bags are squared. This will also help to keep them square as you move them around.  Remove the 2 screws on the front inside as you will be cutting this area off.  Cut the 2 side mount tabs off to get them out of the way. Will also be cutting the top bag mount tab off. Carefully cut the outside lip off using a 4" -4.5" cut off wheel on the grinder. Then cut the inside lip off. You will be cutting the rubber seal off in the area. Don't worry as it will be sealed when the new center floor in installed. Carefully sand the lip smooth to bad inner & outer edge. The dotted line in the picture shows where the floor will be mounted with pop rivets. Check out the pictures. Tools needed so far: Drill & tap Home depot $8.00 Heavy Duty 4-1/2" Angle Grinder Harbor Freight $29.00 (on sale $19.95) Package of 4.5" disc. Harbor Freight $15.00, comes with cut off, sanding & grinding disc.  Next step will be to build the floor. To be Cont.! Since the floor for the GL1800 is fairly flat ( unlike the GL1500 ) with a curve in the front, I'm going to experiment using one layer of mat to shape it. It should be flexible enough to trim to fit & make the curve Using some Tile Board ( Home Depot ) lay one layer of 1.5oz mat and apply resin, roll it out & let cure.  Make a card board patten of the floor to tranfer to the fiber glass sheet made.   OK, cut the floor shape out of the sheet of fiber glass. I did it went it was gelling but not completely cure. Slide it under the bag braces & tape it down & let it finish curing.   The single mat has harden but still a little bendeee. Remove the masking tape which was holding it place. Removed the top brace to be able to glass it easier. Tape up the outside area with the plastic tape so the glass won't stick to it. Laid 2 layers of 1 1/2oz mat on it & rolled it out. Waiting dry time now  The resin has dried so I removed it & cleaned up any boo boo's on the bags. Trimmed the edges. & check for good fit, GREAT! Will brace the outside of the floor as this is now the mold. The floor will be part of the KIT if I get any looker or buyer You can go ahead & rivet the floor to the bags. Make sure the metal brace on on & the bags are square before doing that. Check out the pictures for the nice fit. The outside will be smooth.    This morning I cut up some 2x4 for bracing of the floor. Used the resin putty to attach & will lay 2 layers of mat around them. Will also add some cross bracing Doing this as I will be using this as a mold.  Finished added the wood braces & fiber glassed them on to the floor panel.  OK, so here's the mold for the floor. Waxed it 5 times & spraying the release on it now. May have a floor by this evening.  Apply what I had left of the BLACK gel coat & it's now cured. Laid 3 layers of 1.5oz mat & rolled it out. It's now sitting out in the nice warm sun.  The floor is finished. Trimmed & Installed the floor with 3/16 Alum. pop rivets. Install both metal braces & be sure to square the bags before you rivet. Be sure to apply the silicone sealer on the ares in front where the bags were trimmed earlier. Apply sealer along the back edge of the floor panel were it goes to the center filler panel. After all rivets were in tight, apply sealer along all edges inside & out, smoothed with finger. Also use whats on your finger & cover all rivets. Will be making an "L" bracket which will mount off of the center reflector to the floor. Will spray the bottom with rubber sealer to further help seal it. There will be a vinyl bra snapped on to cover the front floor area. This way no painting will be needed. At this time you could make a vinyl cover for the top which can snap on, as on the "Tag-A-Long" bags. I will be making a fiberglass hard top for it. Addition tools needed: Hand Riveter Set Harbor Freight $5.99 (on sale $4.99) 3/16" rivets box of 25 Home Depot $3.00 1 Tube of silicone sealer Home Depot $6.00 Clacking gun Home Depot $5.00  Made a special License Plate for the Travel Bags, Can be made in assorted colors. Think I was a little shaky on the close up 1st picture, need my AM coffee   Last edited on Mon May 3rd, 2010 12:54 pm by skip20 ____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Mon May 3rd, 2010 12:52 pm | 2nd Post |
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That looks great. Do you have any pictures of it fitted?
____________________ Alan Fitzpatrick. |
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| Posted: Mon May 3rd, 2010 01:04 pm | 3rd Post |
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This is the only bike with with a hitch right now. It's sitting in the weeds right now  
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Mon May 3rd, 2010 01:22 pm | 4th Post |
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What a cool idea
____________________ 03 Honda XR650L 84 GL1200 Aspencade |
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| Posted: Mon May 3rd, 2010 01:25 pm | 5th Post |
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What's the red car with the wire wheels in photo #1??
____________________ Rusty. Enthusiast of things that ride, drive & fly. No one had seen Tigger since the 6:10 Southbound Freight. He was last heard to say: "Tiggers can do anything!" |
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| Posted: Mon May 3rd, 2010 01:27 pm | 6th Post |
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looks Like MG Last edited on Mon May 3rd, 2010 01:28 pm by Lightin ____________________ John3:16 The Road is long winding hilly flat hot cold sun stars AINT IT FUN!!!! 1st bike 125HD in 1969 250Honda Dream 750Honda 10 HD 89aspencade 1994 GL 1500 Trike Past ------------------- 91HD Maybe Trike project |
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| Posted: Mon May 3rd, 2010 01:28 pm | 7th Post |
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rgbeard wrote: What's the red car with the wire wheels in photo #1?? !973 Restored Spitfire.
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Mon May 3rd, 2010 01:29 pm | 8th Post |
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Well I wasnt even close
____________________ John3:16 The Road is long winding hilly flat hot cold sun stars AINT IT FUN!!!! 1st bike 125HD in 1969 250Honda Dream 750Honda 10 HD 89aspencade 1994 GL 1500 Trike Past ------------------- 91HD Maybe Trike project |
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| Posted: Mon May 3rd, 2010 01:33 pm | 9th Post |
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Lightin wrote: Well I wasnt even close You were close, they are both English.
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Mon May 3rd, 2010 02:10 pm | 10th Post |
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With the trike in the garage I got some newer picture of the Travel Bags. 1st pictures shows the GL1500 which will go with the trike when I sell it.    2nd pictures shows the GL1800 Travel Bag before I made the lid.   Last edited on Mon May 3rd, 2010 02:21 pm by skip20 ____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Thu May 6th, 2010 01:25 pm | 11th Post |
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Question Skip???? Will these Travel Bags get in front of the stock license plates on 1500. and 1800's ?????.....These travel bags would look great on my 1100, but I have after market light bars and my license plate is a little lower than "stock" mounting.....Will this be a problem with the local PD's?????? Other than that I like the design and think that later on this might be the answer to not pulling my pop up camper on just a "day trip".... Claude.....
____________________ THE NATION WHICH FORGETS ITS DEFENDERS WILL ITSELF BE FORGOTTEN 1982 GL-1100 Goldwing Interstate...Old Red 1982 GL-1100 Goldwing Interstate...Black Beauty 1994 GL-1500 Goldwing Aspencade...401K.... http://www.RudysBackyard.com |
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| Posted: Fri May 7th, 2010 01:38 pm | 12th Post |
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Went to junk yard & found the tail light sockets, bulbs & wiring. So this morning been building the harness which will go up to the bike. Standard 4 pin plug in.  Last edited on Sat May 8th, 2010 02:37 pm by skip20 ____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Sat May 8th, 2010 02:37 pm | 13th Post |
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OK, back to work on the 1800 Travel Bags. Starting to form the fiber glass lid for it. Cut & shape the 3/8" form board I have laying around to fit the sides, front & back. Will also be adding 1/8" Tile board this time to make a better mold. Been wetting the top & side pieces to be able to bend them to fit. If I'm lucky, may Have it finished by tonight & be able to make the mold on Sunday. That all depends on the bending of the top which I had trouble with on the 1500 model & gave up on the idea for it. Designing this lid a little diffident for a better fit as there may not be a rubber seal on this one.  Last edited on Sat May 8th, 2010 02:42 pm by skip20 ____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Sat May 8th, 2010 07:06 pm | 14th Post |
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Here's a picture showing the SUPER BENDER JIG. Wet the back side & add weight. 
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Sat May 8th, 2010 09:27 pm | 15th Post |
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Still bending the Tile Board. There are 2 sides, 1 rear & the top I need to get shaped. Will lay the top on this evening hoping to get the finish bend. Then will need to trim the top & glue everything together. In the AM. 
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Sat May 8th, 2010 10:17 pm | 16th Post |
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Tops (small crack in center but OK) on & clamped down for the night. See you in the morning.
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Sun May 9th, 2010 01:54 am | 17th Post |
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skip it looks like it would be much easier to just cut some plywood in bows the shape you want them. then screw or glue some thin lexan or just cheap thin board to the bows. just like they do the boat mold. you can use the lip of the bags for the pattern then fill the screw heads and edges with clay or filler? no clamping no waiting. just a thought. Last edited on Sun May 9th, 2010 01:57 am by skoto1 ____________________ just do it and ask questions later. if you never start you'll never finish. PGR # 190570 cc permit none at the present running. but looking gl 1988 1500 trike sold 2003 flhtuci sold gl 1986 1200 trike sold gl 1984 1200 trike sold first bike cb 160 honda to many to list in between |
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| Posted: Sun May 9th, 2010 09:26 am | 18th Post |
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5AM, the curved top came out nice overnight. Used double stick tape & mounted the side panels to the form spacers. Applied form glue caulking along the top edge & placed the top panel in place, Clamped it down. Wait for it to dry then trim & round over the corner. Prep for mold making. Today will be finishing the car top holding rails I mold for the pickup bed cover. Got it in junkyard from Land Cruiser, widen it to fit the cover. It's painted & ready to mount, I hope. Got it mounted. Rest of the day was mostly yard work & clean up, then over to mother in law for a good steak dinner.
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Sun May 9th, 2010 09:34 am | 19th Post |
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skoto1 wrote: skip it looks like it would be much easier to just cut some plywood in bows the shape you want them. then screw or glue some thin lexan or just cheap thin board to the bows. just like they do the boat mold. you can use the lip of the bags for the pattern then fill the screw heads and edges with clay or filler? no clamping no waiting. just a thought. Tried that on the 1500 top in a way & I must have screwed up because it warped on me. Will be glassing this one as it sits on the bags with 2 layers of glass. Then can take it off & add more.
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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| Posted: Wed May 12th, 2010 10:10 am | 20th Post |
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Getting the lid plug for the GL1800 Travel Bags ready to lay up a mold. The mold is made & the release has been washed off. 
____________________ USMC, Vietnam Combat Vet. 69-70, GWRRA 78111 PGR 255645 1st Bike Honda Dream 150 Dream Bought in '68 1st GoldWing GL1100 1989 GL1500/6 (NEW)Still have runs GREAT 1993 Gl1500A Trike Build SOLD Now:1993 Gl1500SE Future Trike To many projects to finish |
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