Custom EN500 Saddlebag Supports

August 15th, 2006

Why pay over $100 when you can make your own for under $10? I finally had had enough of lugging a backpack around with me just so I could carry my sunglasses case. So I broke down went off in search of saddlebags. I wanted the largest I could fit on my Vulcan 500LTD. The after market is not too friendly to 500 riders, as it is considered a "starter" bike. I measured the space, and dragged Marlene over to Iron Pony and picked up a set of Tour Master nylon slant bags (large). They just fit the space. I don’t think I could get anything larger in there if I tried. Now for the supports. Kawa wants $103 for their set. To heck with that! I went to Lowe’s early one morning and picked up the parts to manufacture my own custom set for under $10! Ha ha! I am een-veen-see-ble!

This article includes a materials list and instructions for building these cheap but strong supports.

Parts List

• 1/16" × 1/2" × 3/4" × 4' aluminum angle stock
• 1/2" × 0.194 × 1/2" nylon spacers
• 10-24 × 1" round-head machine screws and nuts

Tools Needed

• hacksaw
• file
• screwdriver
• 3/8" socket/nutdriver
• 8mm socket/nutdriver
• 10mm socket/nutdriver
• drill
• 3/16" drill bit
• 5/16" drill bit

Instructions — These instructions are for constructing a single support, suitable for either side. Repeat for second support.

1. Cut angle stock into two 6″ and one 7-3/4″ sections. (photo)
2. Cut angle into narrow edge of the top ends of each of the short sections. This will prevent the angle stock from digging into the back of the bags. (Thanks to Marlene for suggesting this modification!) (photo)
3. File all the rough edges.
4. Arrange the sections as shown. (photo)
5. Drill 3/16″ holes near both ends of the two long sections. Be sure to drill through the long (3/4″ wide) edge.
6. Drill 5/16″ holes near the top ends of the two short sections. I did this all by hand, and didn’t measure the precise locations of the holes.
7. Fasten the sections together using the machine screws, nylon spacers, and nuts. (photo)
8. If, after assembling the sections, the holes in the top of the two short sections do not come together enough to line up with the holes on the bike, then cut notches in the narrow edges at both ends of the long section. This will allow the two short sections greater flexibility in positioning. (photo)
9. Repeat for second support.
10. Install supports using existing bolts. I use large Tour Master nylon slant bags. (photo, photo)

Entry Filed under: Motorcycle Projects