I am working on a plate that bolts at the 3 on the plastic rack and extends forward to pick up the 2 bolts just behind the seat. It will have tabs around the front-sides turned down and 2 on the rear turned up. It will be cut on a water jet and have cut outs to lighten it up some. It should stiffen up the rear rack quite a bit and will be larger than the stock rack.
I've always liked TCI's products, but for some reason I forgot about them when having this discussion. I just shot them an email though. Hopefully they will be interested in making something for us. I'd love to see a Sequoia type system for the TR. Here is the one of their options they did for the TE630. https://tciproductsusa.com/index.php?main_page=product_info&cPath=144_155_197&products_id=755
We need a TR650 for prototyping in Orange, CA. See thread below. http://www.cafehusky.com/threads/tr650-needed-near-orange-ca.33786/
Ruggedexsposure over on the ADV terra thread is thinking of fabbing some rear racks and is looking for some input.
Got these pictures from BRMoto, Obviously a prototype subject to change I *Obviously* think this qualifies as a BEEFY rear rack.
Got my pipe bender in the shop today... and messed around with a piece of scrap. After I get the valve clearances checked and some other maintenance done, I will begin designing a new rear rack. If its something I want to waste my time on, and like the design, I might sell a few.
I am having an extended plate made that will cover the stock plastic plate and use the 3 holes as well as the 2 holes up front that mount the SW Motech pannier brackets. I will machine a couple of tapered spacers to let the plate sit level and have a total of 5 fasteners in it. There will be tabs at the edges to tie to. I will post up A photo when I get it from the water jet guys.
I like the BRMoto rear rack mock-up a lot. I'm thinking that I'll go with them for the side racks, it's looking like a rear rack will also be in the cart. Hopefully these come out soon.
I don't have the measurements on me, but the OD is 7/8". Its basically the same as the handlebars but with thicker walls. You can see the thickness better in the 1st pic.