This is my design of the roof top storage lid.
CO
https://www.youtube.com/watch?v=Pj8VlufgWJ8

Pretty cool set up. I didn’t have much extra headspace in mine, and I’m kind of a short guy. No problem wearing a helmet?

Actually that's a good question.
I don't drive this machine and it also has an aftermarket seat so that means it's higher than the stock Honda oddy seat.
I will have to put beer poacher in this thing with his helmet on and post another video.
CO

Here is what the clearance looks like:
https://www.youtube.com/watch?v=ygxrgVe4UaE

The bottom of the pan for the roof top storage is level with the bottom bolt on the front down tubes. If you take a string and tape it to the bottom of the nut on that tube and run the string to the bottom bolt on the rear down tubes, that's the height.
CO

Looks Good...

I have one the the original above fiberglass storage units for the FL400
I don't really use it as much as I though I would.

If your producing these for the FL350 I may be interested as I have a couple FL350 machines still on my todo list

Great to see different ideas/products still being created for the Honda's

Dennis

Looks like he has plenty of room.

Actually that was me, I couldn't wait for beer poacher.
It would be easy to make these shorter or longer if that's what I needed.
I have only made this one and don't plan on making any for my other two machines.
This was just an experiment to see what I could come up with.
I have wanted to make this for years, ever since I seen those fiberglass lids for the Pilot. At the time I thought the fiberglass was going to be a mess and very time consuming to make. I do really like the design of the fiberglass lids but I really wanted a metal lid for safety reasons. I even thought about making a mold for the lid similar to those fiberglass ones and then stamping them in metal using my hydraulic press but the plastic boxes and the original metal lids were just the fastest solution.
CO

Pretty good ideal!

very good, and it appears you are getting the vacuum former working great.

Yeah there is a lot to learn and I didn't realize it. It just looked simple.
Vacuum forming lessons learned:
1) The 1/8" ABS plastic forms well at 185'F approx. EDIT: 285'F
2) It does not have to be a tight seal to the heating elements -- in fact it worked better with a small gap.
3) While heating the ABS it actually deformed the clamp frame.
4) The 1/16" ABS plastic will blow a hole if it's heated to the same temp as the 1/8" ABS, it needs to be cooler.
5) You must have good support around the entire piece you are trying to form. While trying to vacuum form the master cylinder side covers the ABS deformed the entire side cover by bending down the edges and warping the mold pieces. You pretty much have to make a wall around the entire edge of the piece you are planning on copying. Support must be very good and strong. There is a lot of power when vacuuming ABS.
Watch the two videos: Storage lid bottom and Ed master cyl covers
6) Female mold better than male mold because of webbing.
7) Parts get very thin in some areas because of the plastic "stretching" over the mold.
8) Possibly copy the part I want to make with plaster of paris ? This idea was first posted by Kuma in one of my threads on the vacuum former.
CO

Success! I liked watching your series of vac former attempts.