BMW R1100RS SEG motorcycle radio box conversion

Luggage conversion. permanently fitted top-box

BMW R1100RS motorcycle SEG radio box conversion

Completed box fitted to a standard 1999 R1100RS motorcycle

(Disclaimer: no resposibilty is taken for these notes or any modifications to any BMW motorcycle, for reference only). I was looking for a small top-box, that fitted closely to the body of the motorcycle, Many after-market boxes are fitted in such a way, that they stick out some distance from the motorcycle. I was looking for something that looked as though it was designed for the motorcycle, Conformal. Also I haven't carred a passenger for decade so did not realy need the rear seat.

BMW made a radio-box for the BMW R1100RS motorcycle and this was fitted to some 200 Metropolitain Police Special Escort Group machines that were seen about London. The box seemed to be about the right size, and looked well made. These SEG machines have been retired from duty and are around on the second-hand market for reasonable prices. Some new owners or dealers, remove the radio- box becasue it doesnt have much usable room inside. Any changes were to be reversable: all original part were not altered and could be retrofitted as required. On looking inside the box., it appears not to have much depth. In order to use more of the space, I cut out a large rectangle from the radio plate, the same size as the supporting frame. Small un-used brackets were also cut off. The original motorcycle rear-seat lock was completly removed invluding the long tunnel and the lock barel re-used on the lid.(After prseeing in the lock pin, the barrel can be pulled out of the long tunnel and fitted to the box lid using a reverse process). All the metal parts were painted gloss enamel black. Some protective edging was added to cover the sharp edges and car boot-interior carpeting added to the inside, making a smal, usable top-box.

A further improvement, to make even more space, would be to remove the radio-plate complety and make a new lower box shape out of 1mm mild steel plate. I may have a go at that later on. as it would mean there would be room for one helmet .

Pictures show the parts that should be supplied with the box
2 painted side panels, 2 pannier rails, 2 black side panels, box frame, lid. rear light unit
and 2 white light unit underside covers 		box showing radio plate
Radio plate Rectangular frame
List of parts:
  • 2 painted side panels
  • 2 pannier rails
  • 2 black side panels
  • White box frame
  • White box lid with lock and strap
  • Radio plate with edging
  • Rectangle frame
  • Light unit
  • 2 White light unit underside covers
You will need. some car boot felt material from a motor factors, Set of allen keys, metric spanner set. Eletric drill and some metal HS drills, a hand saw, and or a electic/router with metal cutting blades. To cut the radio plate, I had to clamp it to a bench, and cut it in short sections, then clean up with a grinding wheel and hand files.
The rear bodywork, indicators, two side panels are removed from the motorcycle. in the picture on the right, the two blue side panels are still in place here.
The rectangular frame has two mounting lugs that fit to the rear of the motorcycle frame. This also has a cross piece revited in place. I removed this piece by drilling out the revits. (part shown here in red ) , so that it gave more room in the final box.
Picture Below: Next the radio plate was marked out with the ara to be cut away, shown here by the silver line This is best accomplished by using an eletric router and metal blade, cutting at 1mm / second, with plenty of cutting oil. Takes about an hour to cut all the way round. Picture Below: This is the plate after the material was cut away. painted black and the rubber surround added. Mounted on the metal box frame , which is bolted in place using the pannier rack mounting holes.
The original R1100RS rear-seat lock barel was removed from the lock tube and fitted into the lid lock. Both locks can be removed by pushing a small wire, or paper-clip into the hole in the side, this pushes in the brass locking key. This means the bike key is used for the lid lock.

Pictures below: The pannier rack mountings, side panels rectangular box were assembeled and the modified radio plate mouned on top. two plastic strips, shown here in white were added to the cut edges. The boot carpet material (not shown) was cut to shape by making a paper template to fit down inside the rectangular box folding the edges over, then cutting the material to the same shape, and held in place at the top with the lid frame mounting screws.

Box does not appear affect the handling. I would prefer to paint the frame the same colour as the rest of the machine, leaving the top in White. The R1100RS colour: Dolphin Blue and the paint code does not correspond to the same colour in the BMW paint code list. May try RS Bike Paint.

POSSIBLE SOURCE of Boxes: Motorworks or MotoBIns in the UK sometimes aqire an SEG RS, or have some boxes after they have converted the bikes back to standard.

Added a rear LED red light strip , supplied by Nippy Normas.
Added a rack on top of the box lid, made from glass fiber tent pole rods and steel tube.
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