KARK Tool Box Cover
I like to have a good selection of tools handy whenever I go anywhere on my bike. As a rule, these will include: open and ring spanners (6 - 14mm); tyre lever; pliers; 19mm combi-spanner; plug spanner; screw driver set, allan keys; 24mm ratchet socket, and; a roll of insulation tape.
Having freed up the old stock air-filter compartment for storing my tools by KARKing the air-box, it occurred to me that there was very little actually holding them in place other than the Bonnie's metal side cover. However unlikely, it remained a possibility that they might rattle out somehow. So I made an adjustable fabric cover to keep them in place. Here's how...
Materials [above left]: waterproof bag/jacket off-cut; 7 inches (175mm) of webbing; adjustable clip fastener, plus; 65/35 polycotton thread. Also the old snorkel bracket for measuring against.
First, cut enough material to easily surround the old snorkel bracket [above right].
Next, sew the edges over to form a hem on the inside [below]. Note the wider overlap down the straight edge which corresponds with the forward facing side of the former air-box.
Cut the webbing into two lengths: one of 5 inches (125mm), and; one of 2 inches (50mm). Feed the 5 inch length through the adjustable part of a clip fastener and sew the free end over firmly [below left]. This will afford grip and prevent the fastener from slipping off.
Fit the 2 inch length of webbing 1 inch through the other fastener and clip the two fasteners together.
Then place the guard over the snorkel bracket so that each end of the straight side is over a bolt hole. Lay the webbing and fasteners on top so that the adjustable end is over the material and the other end is directly over the remaining bolt hole [above right].
Pin the adjustable end in place and sew it onto the material. Sew the webbing on the other fastener together just short of the ends [below].
Using the snorkel bracket bolt holes as a template, bradawl two holes through the material and another through the webbing - taking care not to sever the thread. If you have access to an eyelet punch, this might improve the overall appearance. Fit to the old air-box using the existing bolts plus washers [below].
Very simple indeed - but it works well and, being adjustable, doesn't affect its capacity to hold a load of tools.