400EX Storage Idea

[dudemc]

This is what I did to get more storage on my 400EX. It's an army ammo can. I used the stock mounts for the stock storage container and the rectifier. Had to put some spacers in between the frame and the ammo box so it would mount up straight, and extended the wires for the rectifier and mounted it to the back side of the box with some spacers to space it out from the box. I also used washers on the inside and outside of the box with some silicon to seal it up so far with about 4 or 5 rides and not leaks. I don't do any racing just trial riding and no huge jumps so I shouldn't have to worry about bottom it out on the axle. Just thoguht I would share it with everyone. Had thought about mounting it on it's side under the seat were the brake light is and mounting the brake light to the lid of the box. Thoght that would of been a cool way of doing it.

http://i181.photobucket.com/albums/x212/dudemc/ATV/DSC00139.jpg

http://i181.photobucket.com/albums/x212/dudemc/ATV/DSC00140.jpg

http://i181.photobucket.com/albums/x212/dudemc/ATV/DSC00141.jpg

http://i181.photobucket.com/albums/x212/dudemc/ATV/DSC00142.jpg

http://i181.photobucket.com/albums/x212/dudemc/ATV/DSC00144.jpg

[mineralgrey01gt]

nothing wrong with that and that will definitely come in handy on trails and such

[honda400ex2003]

very nice. you could probably drop it off a cliff and it will not come off with that many bolts in it. that is a great idea. steve

[vaget22]

I like that idea. I think I'm going to have to do that one. When you moved the rectifier, did you splice pieces of wire into the harness to extend it?

[dudemc]

Yeah I added like 3 inches to the wiring

[jcs003]

another good idea. (to balance out the weight) get an aftermarket airbox that moves the battery inside of it. just a thought.

[Newt327]

Thanks man, Great idea! I did this on my 400ex tonight just as you did only rather than extending the rectifier I left room to mount it to the front of the ammo box. I really didnt want to cut those wires.

Here are some pics of mine.

http://i738.photobucket.com/albums/xx21/Newt327/400EX/DSC_0002.jpg
http://i738.photobucket.com/albums/xx21/Newt327/400EX/DSC_0001.jpg
http://i738.photobucket.com/albums/xx21/Newt327/400EX/DSC_0003.jpg
http://i738.photobucket.com/albums/xx21/Newt327/400EX/DSC_0004.jpg
http://i738.photobucket.com/albums/xx21/Newt327/400EX/DSC_0006.jpg
http://i738.photobucket.com/albums/xx21/Newt327/400EX/DSC_0005.jpg

[dudemc]

Cool, I didn't even think to do that. I was just trying to get the box forward as mush as possible, but a good I idea though I really din't want to cut the wires either but made sure I used weather tite conectors and heat shrink tubing.

[quad2xtreme]

sits higher than your exhaust so you will be fine.

I would buy either of these. :D

I use an Armadillo six-pack with a cooler and hate the added weight at the back end plus it makes it harder to put in the trailer with other quads.

[screaminta]

So how are these holding up for you guys? I'm going to trailfest (hatfield McCoy) next weekend and could use some more storage..the trails are pretty rough though... How durable are they? Please let me know

[NMills]

I'm so jealous.... makes me wish i had a Ammo Box... could use the space...

[NMills]

What are the measurements of that box.?????

[screaminta]

I believe it is about 3" wide 7" tall and 10" long

[dudemc]

I havn't had any problems out of mine seems to be holding up good. I would say as long as you use washers on the inside and the outside should be fine. I havn't carried anything real heavy in it just a couple of wrenches screw driver allen wrenches spark plug socket and a strap. I have thought about adding a 1 inch wide piece of metal to go from the bottom of the box up to the seat latch bar just for some more support. Probably doesn't need it but oh well like things to be over done. lol. If I do it I'll add some pics to show you what I did.

[tri5ron]

for some of you newer members who might not have ever seen this, you might like this idea too....

http://www.exriders.com/vbb/showthread.php?s=&threadid=410335&highlight=tool

I like the ammo can too.

[jsl1213]

that's a really good idea! just happened to have an ammo box.
one of the ears broken on original tool box and was thinking of how
to fix it. very timely post.

[jsl1213]

i went back and looked at the pics again. there is a box that's a little wider than that, looks like it would fit. going to try it.

[HIPPYHUNTER]

Over at ADVRIDER.COM the motorcycle guys use a John Deere owners manual tube which is larger than the Honda tool tube...and has a screw on lid that stays on.

[Newt327]

I've had my ammo box loaded up with all kinds of goodies all summer.

I always carry the folling in mine:

Tools - Channel locks, plyers, needle nose, screw drivers, small 1/4" drive rachet set with metric sockets, and a few wrenches 8mm, 10mm, 12mm, spark plug tool, allen wrenches
extra spark plug
knife
Tire plugs and plugging tools
small tire pump (hand pump - Bicycle type)
Electrical tape
small section of wire
flash light
tow strap
toilet paper

maybe a few other things i forgot but as you can see you can fit a lot of stuff in that ammo box as long as you arrange it correctly.

I've had 2 problems so far with mine.

First i found that since i mounted the rectifier on the front and bent the wiring harness at a 90 degree angle one of the wires was rubbing against a bold and kept shorting out blowing my main fuse. I've since insulated the section thats bent with some plastic wire loom and it seems fine now.

second issue was with all the stuff i had in there the weight of the tools and stuff started to bend the ammo box. If you look at the pictures i posted earlier you will see i only use 3 bolts to support the box. I've since put a 4th bolt in and it seems more stable now. I've thought about putting a strip of steel accross all of the bolt on the inside of the ammo box to reenforce it but it seems ok right now.

This was a great mod and if my ammo box ever falls apart or breaks, i'll get a new one a replace it. It's great having all those tools available out on the trail. We've used everything in that box at least once this summer. I would definatly reccomend this mod to anyone out riding the trails away from camp.

[Newt327]

Also, my ammo box is a .30 Cal ammo box. Each different caliber box is a different size.

[rmcfadden68]

Originally posted by screaminta
So how are these holding up for you guys? I'm going to trailfest (hatfield McCoy) next weekend and could use some more storage..the trails are pretty rough though... How durable are they? Please let me know looks great i travel to mann,wv several times a year and it`ll hold up!! sweat idea guys. there just happens to be a surplus store at the other end of town. will be there tomorrow. enjoy hatfield. dont stay in gilbert,wv. a bunch of pill head thieves down there

[screaminta]

that stink I am staying in gilbert, but its at the twin hollow camp ground. Apparently they dont let you in without a pass so I guess i should be ok, we stayed there last year with no issue..

[rmcfadden68]

Originally posted by screaminta
that stink I am staying in gilbert, but its at the twin hollow camp ground. Apparently they dont let you in without a pass so I guess i should be ok, we stayed there last year with no issue.. im not real sure about the campgrounds. we stayed at a motel that had a bar attached to it outside. several contractors from loggers to railroad workers were there. and a couple of people there to ride. the contractors trucks were broke into and 1000`s of dollars of tools were stolen. ironicly they were all found at local flea market and they had to by them to get them back. state police hung out in bars parking lot all night. 1 quad was stolen. police found it. pulled a girl over for dui. she was ridin it. we pulled our trailer in a broken car wash. chained all 6 bikes to trailer and then to each other. we blocked both ends of the car wash with our pickups. also was approched by two very cute young girls"lookng to make a little extra cash". bolt it down if ya wanna keep it. but have a great time the place is a great place to ride.

[Ian400ex]

08's can't do this anyways. :D

[inv3ctiv3]

This looks really cool I think I wanna do this.

[screaminta]

I just completed mine and I love it!! I used 2" fender washers both inside and out on 3 of the 4 bolts holding it on, and I bolted the regulator to the front behind the battery. I am going to trailfest, and so far I have put:

4in1 screwdriver
Visegrips
Laminated trail map
Small led flashlight
Spare(old) clutch cable
Spare clutch lever and perch
Extra spark plug
Stock plug wrench
4 spare 8mm bolts
Zipties
Electric tape
Leatherman tool
Metric Allen wrench set(flip open style)
8/10mm,12/14mm open end wrenches
10/12/14mm combination wrenches
4-12mm 1/4" drive socket set w/ ratchet
13-19mm 3/8" drive sockets w/ ratchet
(2) 2" 3/8" extensions
3/8" - 1/4" adapter

Yes it all fit nice and snug believe it or not!! If I knew how to post pics I would show you it all laid out and tucked in

[4strokernow]

What way would you guys go with the regulator: 1. Extend the wires and hang it on the side or 2. Put it on the face of the box in-between the battery and the box?

[screaminta]

I went with putting it in front of the box and not extending the wires... I'll let everyone know how it works out after this weekend. The trails there are pretty rough, and if it lasts through roughly 250+ rocky miles then I think it should be fine

[rmcfadden68]

id go between box and battery seems more protected. and id think a mounting spacer of some kind if it needs air to stay cool.

[Newt327]

Originally posted by screaminta
I went with putting it in front of the box and not extending the wires... I'll let everyone know how it works out after this weekend. The trails there are pretty rough, and if it lasts through roughly 250+ rocky miles then I think it should be fine

Just make sure the wires dont rub against any of the bolts so you dont have the same problem i had. Put some plastic wire loom around the harness where it bends or something else to insulate it well. Mine held up for a few months but all the movment from riding eventually wore through the insulation on one of the wires and kept blowing out my main fuse.