1983 Yamaha Venture trunk build for 1500 Nomad

[Work4crown]

Update: It seems that Photobucket wants to charge to host photos like the ones used here to document my trunk project. I think they may eventually remove all the photos if I don't start paying for their services. So I have saved these 3 forum pages as pdf files into my Google Drive account just in case.

Here is the link if anyone is interested:
https://drive.google.com/drive/folde...P7?usp=sharing

So I've decided to do a Venture trunk build based on what I've seen others doing here and around the web. I felt like I had a few ideas I hadn't seen before that you might find interesting so I'm going to share it here.

I bought a 1983 Yamaha Venture trunk from Ebay for $40. I feel like the overall quality, paint, metal, pad are all in good enough shape to work with. I don't think it will need much repair.








I didn't realize at first that I would want the quick attach bracket and ended up buying one from Ebay for $30.


There are some holes and cracks in the bottom that seem to be in the usual locations from what I've seen. I plan to use ABS plastic plumbing fittings, ABS cement to fix it up as I've seen people discuss here.
http://goldwingdocs.com/forum/viewto...&t=3246#p13182


At first I starting out using C.A.D. (Cardboard Aided Design) to get a feel for how this would look on the bike. My plan was to remove the sissy bar and luggage rack but leave the offset brackets to mount my new bracket to.

When I mocked it up in cardboard I didn't like how the part had these tabs sticking out.


New plan: Remove the sissy bar offset brackets and mount my new bracket directly to the side rails of the bike.




I drew up the bracket in Solidworks. The plan is to use some 12 gauge steel we have and powder coat it Chrome or Black.

[Work4crown]

My friend (who is going to make this bracket) said it was too boring and suggested I add some curves and features to it so I drew this:


He was like "Woah...settle down there...I don't have a lazer cutter or anything...we're just going to make this on a mill."

So I re-drew it without the artwork:


He asked me to break it into 3 parts to make it easier to mill:


and we can weld it afterwards:


I started to think it would be cool to use quick release hardware instead of nuts and bolts to secure the two brackets together so I found this:


Here is the idea of the assembly:






I found a cheaper quick release lever:

[Work4crown]

I thought it would be cool to add gas struts to open the trunk as I have seen on some trunks:
http://www.venturers.org/Tech_Librar...=002004&id=372

I found this lift rod design guideline:
http://www.boatingmag.com/installing...pports?image=0







I saw a guy added some automotive carpeting to his trunk that looked real good. I'm thinking about that as well.
http://graywarrant.us/nomad/Mod_Albu.../DSC02615.html


I thought the use of the automotive Nomad 'V' and script text looked really sharp. I would probably need to find them in Chrome to make it match my colors.


Last I think it would be nice to rig up a light in the lid for night use. I don't want to wire anything in so maybe just an LED flashlight or something.
I did see there is a $25. product already made that just sticks on:
http://www.thetoplite.com/PN300224_detail2.html

(According to the Top Lite website part number 300224 is made for "Yamaha touring motorcycles such as Venture with flip open top trunk.".)



It looks like if you wanted to make a Harley style quick attach set up for the bracket it wouldn't be that hard. Just slot the mounting holes and add some inexpensive hardware from Ebay.







So for now I need to fix up the bottom of the trunk box and in 2 weeks we'll make the bracket. Then I'll get some quick release stuff on order, and consider what I should add to it. After tax return comes I'll get the trunk painted. That's the plan. I'll come back and add more pictures later.

[Bud2rat]

Nice looking setup. I, too, mounted a 2nd generation Venture tourpak. I mounted mine to the stock backrest rack using some vinyl loom clamps and some extra support brackets mounted to the fender rails and the bottom of the trunk. https://www.google.com/aclk?sa=l&ai=...%3D%26mp_mt%3D

[Navigator]

Most impressive and I look forward to seeing the final results.

[Chuck A.]

Looking good!

[Loafer]

Nice!

[Jared]

Wow, nicely thought out!

[dale55]

Nice job dude! Wish you lived around dallas I would get you to make me one of those!

[Rasta]

Looking good !!

[eg78]

Awesome, look forward to seeing the end result

[BudMan]

oldbikers had a Venture trunk on his Nomad and it looked great.
At $40 I think you got a heck of a deal. The pad appears to be in great shape.
I think it's safe to say your not the kind of guy to do something with a plan.
Nice work.

[radco]

Looks great! A pic when done is a must! :)

[vex918]

I am liking this

[Work4crown]

So I got a little further on the trunk project. I removed the Yamaha emblems, the seat cushion, the top rack from the box. The design is finished, the mill is programmed, the steel, quick release levers and Oatey ABS cement are ordered.

I made up a final cardboard model to make sure I liked the fit.





I realized since the front of the trunk doesn't overhang the front two mounting points I should be able to mount the quick release levers upside down in the front and have access to them from the top side. Whereas the lower levers will still have to be adjusted from underneath.



I wanted to measure the two bracket mounting bolts at the back of the bike to see if they were level with the ground but I didn’t want to buy a special tool. I found an angle measurement app for my phone that can be calibrated and seemed pretty accurate.



I also got a little further with the gas strut mounting because a friend gave me 2 Guden GGS43-030-K gas struts for free! I’m not sure if I will use them – I need to test them out to see how 30 pounds will work.
http://www.guden.com/Control/Gas-Springs

I found that on the internet people are reporting spending $20.-$30. For a single gas strut and $4.-$6. For a 10mm ball stud to mount with. Since I already had Guten struts I decided to check out their website and found the following typical prices: $10. For a strut, $0.75 for a ball stud and $2. For a mounting bracket that has a ball stud already in it. ($10. minimum order)

After looking at all the premade brackets I think I might make my own because none of them really would fit the way I want. http://www.guden.com/Control/Gas-Springs



I think I'm going to mount the trunk lift strut like this. I'll have to add a hole to the trunk box at the top and then drill out some holes in the bracket to match. At the bottom I'll need to remove the metal bracket in the trunk, remove the little bracket that holds the nylon strap, drill matching holes in the bracket, mount my new bracket and then re-mount the bracket that came with the trunk. I also plan to cut the u brackets to remove the unused flanges.

I weighed the trunk lid, chrome luggage rack, seat pad and handle. I think they weigh about 12 pounds. The lift rod I have is a 30 pound strut. However, when I used the formula from the Boating website to calculate the required strut pressure I got 29.87 pounds. So...one of those struts should be perfect. If you wanted to use 2 struts maybe 2 15 or 20 pound struts would be good.


The box will be able to open this much with the strut.


The quick release skewers came in so I tested them out with the card board. Everything fits but I'm going to have to cut down the skewers threads that mount towards the back of the bike so they don't interfere with the trunk box.


Started cutting the brackets on the mill...brackets should be done this week. Welding next week.