Sealing holes in hard cases?

[Wildroamer]

Hey gang,

In line with my thread about planning next year's trips, I'm trying to get my gear and luggage situation sorted out.
I have set up a pannier system using the Pelican Storm iM2435 cases. These come setup like a rolling suitcase, with the little wheels and collapsible handle.
After removing that stuff, I'm left with two holes on each case, where the handles were attached.
Any thoughts on how best to seal these up, neatly, so the case will be waterproof again?
I've considered taping one side, then filling the hole with silicone caulk. Not sure if there might be better options, so I thought I'd throw it out here. Holes are maybe 1/4" - 5/16" (6-8mm) in diameter.

Thanks for any ideas!

Todd

[antmanbee]

JB weld or hot glue would probably work or auto body filler.

[Perazzimx14]

2 layers of masking tape on whatever is the finished side then drizzle some 5 minute 2-part epoxy or JB Weld (it'll self level) and let set up. I
ve done it on mutiple Pelican/HF cases with excellent results.

[Wildroamer]

Excellent! Thanks you two!

Think I should double the tape so there is no sticky part over the hole? Or will that peel right off when cured/set/hardened, or what have you...

[Perazzimx14]

The epoxy should go against the sticky side of the tape. The sticky acts kind of like a release agent.

[Tom]

If you want the option of keeping the wheels & handle.  Rubber plugs from Ace hardware.

[Perazzimx14]

If you want the option of keeping the wheels & handle.  Rubber plugs from Ace hardware.

With a Philips screwdriver or drift and a tap of a hammer you can also drive out the epoxy plug if needed.

[Tom]

 

[kingoffleece]

Sugru or Moretight

[Wildroamer]

Thanks for the suggestions! All noted!

Speaking of noted...anyone else get that ad for Bellewholesale at the bottom of the page?!...Talk about ho,ho,HO!😉

[Tom]

Harry & David or Rad bikes.

[malik]

Go with the rubber grommets/plugs - then you can use one as an esky (ice bucket) at rallies.

[Wildroamer]

Go with the rubber grommets/plugs - then you can use one as an esky (ice bucket) at rallies.

I like the way you think! But the holes are closer to the top.

[malik]

Turn upside down to drain. Once it's being used as an esky, it's best off the bike anyway - prevents your drunken mates pushing the bike over in a fumbling effort to find the coldest beer. You gotta plan for these things.

[Wildroamer]

2 layers of masking tape on whatever is the finished side then drizzle some 5 minute 2-part epoxy or JB Weld (it'll self level) and let set up. I
ve done it on mutiple Pelican/HF cases with excellent results.

Used the JB Weld 5 min epoxy. Worked perfectly!

[Wildroamer]

I have the Unit Garage rails mounted, and bought 2 sets of the Quick-release mounts. One set for my leather bags that I used last season, and the other that I mounted on these cases. I've yet to try them out on any real trip. They are set up strictly for one-up riding, as they  contact the passenger pegs.

[malik]

I can see why you've been tardy mounting those hard cases - they look gigantic. Now you've gone to the trouble, they need a test run to determine how well they function.

If you have trouble with heat from the mufflers, you could try fixing some silicone sheeting on the bottoms of the bags, glue or self-adhering Velcro. The silicone from baking trays is supposed to be good for 500C.

[Wildroamer]

Yeah,  I'm not sold on them either. They are bulky for the 25 liters that you get. I frankly would probably be fine with my leather bags and the bag on the passenger seat.
I can always put these mounts on different hard cases, but the cases are so damned expensive, even without their mounting systems. This seemed like an economical option, but not loving the look of it.

[wymple]

I plug holes with round radial tire patches. Put them on the inside and dress the outer side any way you like.

[ahaussmann123]

Sugru or Moretight

Second Sugru!

Previous owner drilled holes in the hard case on mine, similar size to yours pictured. I filled with Sugru, $10 on Amazon. Hardened overnight, good as new!

[Wildroamer]

I can see why you've been tardy mounting those hard cases - they look gigantic. Now you've gone to the trouble, they need a test run to determine how well they function.

If you have trouble with heat from the mufflers, you could try fixing some silicone sheeting on the bottoms of the bags, glue or self-adhering Velcro. The silicone from baking trays is supposed to be good for 500C.

Maybe these are a better option;

https://www.pelican.com/us/en/product/cases/top-loader-case/protector/1430

The problem with aftermarket options is they all seem to require their own mounting system. I'm committed to the one I have, but the mounts are easily put on other cases.

[Antietam Classic Cycle]

A friend has these on his (old) Eldorado and they look great: https://www.pelican.com/us/en/product/cases/ammo-case/vault/v250

[Wildroamer]

Thanks for your suggestion, those DO look nice!
I'm also having a look at the Givi E22N cases. More expensive, but not as pricy as some of the others.

[Perazzimx14]

Thanks for your suggestion, those DO look nice!
I'm also having a look at the Givi E22N cases. More expensive, but not as pricy as some of the others.

For decent case if your open to side loaders check out the local Harbor Freight for Apache cases. The XL 4800 is just a shade smaller then the Pelican 1550 series. At $59.99 minus 20% from the omnipresent coupon they are cost effective and work well.

They also avalaible in several different colors. black, tan, safety yellow, safety orange

[Antietam Classic Cycle]

I use an Apache 3800 as a tail box on my V700. Excellent quality at a reasonable price.

[Wildroamer]

Wow, thanks for another option, and one that I can actually check out! Now to search for some coupons online!
Cheers gang! I really appreciate you all considering my situation and offering your thoughts!

Todd

[Perazzimx14]

I use an Apache 3800 as a tail box on my V700. Excellent quality at a reasonable price.

Having had both the Pelicans are certainly more robust but they are also a bit heavier. The Apache cased are lighter and thinner but  more than adequate for pannier/top case duty. Factor in the price and its a no brainer. I saw no different between brands in water/dust proof-ness

[Perazzimx14]

Wow, thanks for another option, and one that I can actually check out! Now to search for some coupons online!
Cheers gang! I really appreciate you all considering my situation and offering your thoughts!

Todd

If you have a smart phone google Harbor Freight 20% coupon and one will come up. At the local HF they keep a 20% off coupon above the register. If you ask they'll scan it so you don't even have to look for one.

[wymple]

I have a couple ammo cases on an old Suzuki. They are plastic and very light, the metal stuff is really heavy. They don't take on any water and have been as handy as anything short of my standard MG California 2 factory cases.

[Antietam Classic Cycle]

Having had both the Pelicans are certainly more robust but they are also a bit heavier. The Apache cased are lighter and thinner but  more than adequate for pannier/top case duty. Factor in the price and its a no brainer. I saw no different between brands in water/dust proof-ness

I have Pelicans on both the Convert and V700. The Apache 3800 doesn't seem lighter or thinner to me.