Leaking Coocase Box Fix

Coocase Aluminium box, the X-Series comes stock on most of the Benelli TRK 502 motorcycle in Malaysia. Unfortunately, the boxes has defects on it’s bottom edges which leads to leakage.

What is most frustrating that some of us paid and waited for almost 2 months for the Coocase boxes to arrive from China and and only to know that it has defects. Whilst I agree that boxes do leak at certain period of time but I don’t expect it from a brand new box.

I noticed the boxes had water in the bottom when I was riding in the rain for only couple of minutes. I had my Macbook Air laptop in it and can you imagine what will happen to it if I ride it for half an hour?

At first, I thought it would be just mine and a quick check with other Coocase box owners, it seems almost all of them are affected.

I called Mforce (Benelli Distributor in Malaysia) and they said they are aware of this issue and said that I could come over and have my boxes fixed.

I went there last Friday and the first thing I told the person in charge to just take the water hose and spray over boxes and the water was just pouring in around from bottom corner.

The technician cleaned the box and glued every edges/corner with silicone glue using hot gun which fixed the problem but deep inside my thoughts, I know this is just a temporary fix as the silicone isn’t the way forward as it will start to peal off and it does not last.

The outer part was also glued as you can see at the image below. I know it looks ugly, perhaps it would be better if the edges covers been removed first before adding the silicon glue?

I recorded the video below so that other affected owners can DIY themselves on how to fix this (temporarily).

Should the leakage happens again, the only other solution that I can think off is to drill couple of holes in the bottom of the box so that the water drains out?

Moving forward, I’ll also need to ensure that packed everything in waterproof inner liners so that it will not get wet.

Honestly, Coocase should take ownership of this problem and come with a better solution or at least say expect this from our product – or sorry no, this is unacceptable!

4 Responses

  1. Hypocee says:

    Wow, yeah, that was designed by someone who doesn’t know/care how gravity works.

    It depends how much you like the box otherwise, how much tools cost where you are, and how much a different box costs, but:

    If this happened to me and I liked the box, I would buy/borrow:
    A 3.5mm shank rotary tool (Dremel or knockoff) with cutoff wheel for cutting the rivets – ~USD10
    (cut off (from the inside) and remove at least one of the rivets to take to the hardware store or wherever)
    A pop rivet tool and pop rivets that match the box’s rivets – rivets included with the tool match if you’re lucky – ~USD10-20
    Some “bituminous membrane”/”rubberized asphalt”. This is the trick. It’s used for shingle roofing and for “flashing” on window and door frames. Ideally you could scavenge or buy scraps from a roofing or construction job, but more likely you’d have to buy a roll of flashing – ~USD13

    There are all sorts of clever ways you could go with O-rings and gaskets, but RA is magical. It’s indestructible except for sunlight exposure, adhesive-backed, and contracts forever around puncturing objects to form a waterproof, not water resistant, seal.

    Grind off the rivets, undo the bottom screws, cut pieces of RA that fit under the corner bumper and surround all three holes, attach the RA, poke pilot holes, screw and rivet. Hopefully, the result would go from a box with a funnel on each corner to a box that floats in water.

    • Great Share and tips you’ve provided! Anyway, I took my boxes to elsewhere and go it fixed (professional work). They ripped off the silicon glue, took off the box’s rivets and pasted some type of liquid (I can’t remember the name). There is no more leakage now and I love my boxes now 🙂 It’s such a shame that till to date, Coocase haven’t reply to me. Perhaps they don’t bother! BAD CUSTOMER SERVICE!. Thanks again.

  2. Chriszzz says:

    Perhaps you can get a waterproof inner liner for your box, similar to how saddle bag users protect their belongings. It’s sad and surprising that an aluminium box can be leaky. I have a plastic Givi top box and it’s water tight, mainly because it does not have seams like a aluminum box does. Or maybe Givi just has better QC.

    • Hi, this box comes with inner liners but they are not waterproof. I’ll need to look up for one soon and in this case, it is just down to Coocase QC. I’ve emailed them but they didn’t bothered to reply me and that’s pathetic. I’ve used Givi top box for years and never had any leakage issues. I’ll switch back to Givi in the future. Cheers.

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