I got sick of trying to find ways to completely water and dust proof my other rear bag so I decided to start with a plain aluminum box I found on ebay for $100 shipped. I carpeted the sides and the created a wood floor and dividers and carpeted that. I added 4 bolts to each hinge in addition to the rivots. I then strengthened the top with aluminum angle iron and also strengthened the pin area. I drilled out and removed the rivots for the latch and plaque and silicon-ed around the edges and used bolts to secure them. I also added better weather-stripping. I then added the pockets and water bottle holders from my old one. I tested it out last weekend and it is water and dust proof. It actually sat on the trailer overnight and got poured on. The latch system does have a 3/8" x3/8" hole or so underneath the actual lift up latch lever. What I did there was cut a piece of high density foam and put it under the lever to act as a filter of sorts. When you close it you can hear the air try to escape through it from being air tight. It holds quite a bit, as it is 35.5" long, 15" wide and 15" tall. I can now put helmets inside it as well. I added the stickers I’ve accumulated, figured that was a good spot for them….lol
I have three bolts going through the bottom wood floor, aluminum floor and also into the mounting board, mounting the trunk to the mounting board. I then have an additional 2 bolts going through the bottom wood floor, aluminum floor, mounting board and through the rack on the ATV. Then have 4 more bolts going through the mounting board and ATV rack. So I have a total of 5 bolts bolting the trunk to the mounting board and a total of 6 bolting the mounting board to the ATV, using all OEM holes in the rack. Only way that trunk is coming off is if it tears the whole rack off the ATV.
