Smuggler Project

[Riona]

I'm a student at a boat building school. We work in both wood and composites. In addition to the required curriculum we are allowed to use the school facilities (wood shop, composites shop, finishing shop) to work on personal projects, if approved by the college.

I discussed with my Instructor the idea of a project to re-creating this design of Smuggler:

''

I don't carry a passenger, nor own a top box, so this seems a better design for my situation than the Corbin one:

as it fully utilizes the aft luggage rack area in addition to the rear seat space. I do a lot of photography and one use is to carry my camera bodies and lenses, so I can get easy access without risking them falling out of panniers or being in an unsecured tank bag.

Questions:

- Does anyone have any knowledge of the original I am trying to recreate ? I found it on a "smuggler" post on this forum (which I have been unable to find again ) which referenced it as being "fabricated by someone in the PNW" and "possibly using a spare gas tank as part of the fabrication"

- Anyone in the Seattle area have a "real" corbin smuggler that I could take a look at (not trying to copy their design, just want an idea of how it works as pointers for my own design)

My Instructor wants to see a more detailed project proposal, and then he will help me figure out the best way to build it .. He says he has approved other bike projects in the past - mostly fairings.

Initial thought is to build the box using wooden boat construction techniques, then use that to create a male mold from which to build one in glass fiber.

Donations of historical perspective, schematic diagrams, unwanted gas tanks, rear seat trays, lock mechanisms, etc. gratefully received !

Riona

 

[majicmaker]

Go for it Riona! Keep us posted.

 

[ridernotbiker]

As I recall, it's a photoshop dream image by a member, and it doesnt really exist. The gas tank fab was part of the discussion on how to possibly fabricate it.

If you do this, be cool to the original designers of the art and the Smuggler by making it different enough to call your own. (especially if it later becomes a market item.)

Sorry I don't have more than that but I'll watch this thread with interest.

 

[ridernotbiker]

Oh yeah...I little critique I had about that art concept was the front of the "box". Seems angled a bit too far forward at the top and might be annoying to the lower back for those that sit more upright. Just saying.

 

[Riona]

I'm very willing to be cool to anyone with intellectual property involved in this project.

If the original designer / photo-shopper will contact me in PM, I'd love to collaborate on the design - and maybe make a second one once I've gotten as far as mold.

I'm already thinking mine will be lower - half way between the Corbin and the PPS* one. Higher than Corbin as it has to have useful volume over the rear subframe. Lower than the PPS one so as not to be a barrier to "getting a leg over" when getting on / off the bike.

* Possibly Photo-Shopped

 

[Riona]

Oh yeah...I little critique I had about that art concept was the front of the "box". Seems angled a bit too far forward at the top and might be annoying to the lower back for those that sit more upright. Just saying.

Yup - occurred to me too. More of the angle that the Corbin has.

Also at the back end, carry the volume further aft, and make the tail a bit blunter ... echo the curve of the gas tank, or deliberately curve it so a helmet would fit ... though that might make it too tall for the "leg over" process ... Mmmm decisions, decisions ...

 

[maddad]

I started one of these. Have a shell created and attached loosely to the plastic from a Gen 1 back seat. Haven't really looked at it since last summer. Figure be a spring project for me this year. I like the idea of having this larger and cover some of the back rack.

 

[ridernotbiker]

I like your approach

. Youve GOT this!

 

[Riona]

I started one of these. Have a shell created and attached loosely to the plastic from a Gen 1 back seat. Haven't really looked at it since last summer. Figure be a spring project for me this year. I like the idea of having this larger and cover some of the back rack.

Thanks Maddad - love to see pics and learn from your experience so far ...

Riona

 

[Panman]

Cool idea, you can look at mine if we can figure out when to meet up. Or the Auburn Tech day there will most likely be more than one.

 

[David Foley]

Competition is good - there isn't any competition for this particular item and Corbin's pricing reflects that. I considered it a must-have, so I paid my money, regardless of the reported leaking issues. 10 week lead time for delivery so I'm still waiting patiently......

Build a better mouse-trap and the world will beat a path to your door!

Looking forward to see what you come up with.

 

[Riona]

Competition is good - there isn't any competition for this particular item and Corbin's pricing reflects that. I considered it a must-have, so I paid my money, regardless of the reported leaking issues. 10 week lead time for delivery so I'm still waiting patiently......
Build a better mouse-trap and the world will beat a path to your door!

Looking forward to see what you come up with.

Yup $800 was a little too steep for me ...

And one advantage of being in the "boat" program is that my Instructor is unlikely to let me get away with something that isn't water tight ...

For the prototype I'm considering an OEM water-tight hatch like this one ... (to pick one at random from hundreds of hatches made for boats - obviously this one is too big)

https://images.cabelas.com/is/image/cabelas/s7_013744_999_01?rgn=0,0,2000,1210&scl=5.5&fmt=jpeg&id=0-VPUA3khJgQDesj1bWeVd

 

[escapefjrtist]

Echoing Panman, there will be many at the Tech Day coming up in May. Ahchiu, whom you've already met, has a Smuggler plus quite a few other locals.

Good luck with the design...totally cool school project!

--G

 

[Chuck35]

I am very interested in what you come up with. I too wrestle with the temptation to buy a corbin smuggler

 

[ahchiu]

Riona,

I have one you can look at. PM me if you want to meet before the tech meet. I live in the Phinney Ridge area near the Woodland Park Zoo.

 

[Niehart]

Riona,
I have one you can look at. PM me if you want to meet before the tech meet. I live in the Phinney Ridge area near the Woodland Park Zoo.

+1 Woodinville area.

 

[beacher]

Riona, if you can come up with this and make it waterproof, I can pretty much guarantee that you'll be able to sell a boatload of them, if they're a reasonable price. As a camera junkie, I'd love to have a place to stash a camera that's easy to reach, but the Corbin isn't (price wise!).

 

[20valves]

....I can pretty much guarantee that you'll be able to sell a boatload of them, if they're a reasonable price.>>.

And that would be? I hated paying what I did for my smuggler but now that the pain of the purchase is long forgotten, there is no doubt it's one of the most useful bits of kit I have for my FJR since I always ride solo and don't want the high, rearward weight of a trunk.

Oh, and if the "new thing" could utilize the included third lock that comes with FJR's, that'd be sweet icing on the cake. Also, it looks like "new thing" would replace the factory grab bar/rack thing so "new thing" would no longer just lock in place with only the key needed to remove it, correct?

 

[Riona]

OK - had a few minutes before class this morning to push thinking along a bit more.

Estimated Price - you guys are way ahead of me - at the moment its a one off project to be done in the college shop for my own education and benefit. BUT good to know there is a potential market for something like this if I ever get beyond a prototype. So far my project is 4 pages of thoughts and sketches at the back of my notebook and a few photographs.

Using the "third lock" - yes, that is my intention. Its a fairly generic lock barrel with a simple tongue at the end. Reasonable way of locking the lid, First prototype may use an OEM Marine hatch, in which case I would retro-fit the Yamaha lock into the hatch lock mechanism. Eventual design (or maybe even the prototype) will have a fabricated hatch to fit, locked by the Yamaha lock.

One design question I answered for myself was whether or not to remove the factory grab rail / rack.

Pro to removing:

+ Much stronger design as secured by 5 bolts into subframe, not just a single key operated restraint

+ More volume available for storage

Con

+ Requires wrenching to remove so not a good solution for someone who frequently changes between solo and pillion

For me, I never carry a pillion, so having this bolted down to the sub frame and tail is a no-brainer. In fact, I might not even add in the tongue piece that engages with the rear seat release. To steal the box, the thief would have had to break it open, remove the contents and unbolt it. The extra step of breaking the keyed release cable would not be much of a deterrent.