RE's top rack thread

Discussion in 'TR650' started by RuggedExposure, Aug 18, 2013.

  1. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    I'm sure some of you are tired of seeing me derail threads with updates on my rear rack fabrication process. So I made a thread for those interested, and for the sanity of those who couldn't give a rat's ass.

    It all started with the craptastic factory rack snapping in half like it was from Kmart:
    [IMG]

    So I got down to working on a design for a heavy duty one in my free time:
    [IMG]

    I started with making the bend of the main hoop:
    [IMG]

    I fiddled around with the design and angles and ended up with this:
    [IMG]

    Turns out it was a bad idea having a stressed member be composed of 3 pieces when all I had to do was play around with the tubing bender and come up with something better. But I continued with this and made a template:
    [IMG]
    TE250Guy, Scutler and Abby like this.
  2. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    Once I started getting all of the mounts tied in to the hoop I decided my CAD design was too bulky and ended up with this:
    [IMG]

    I then decided MIG was not precise enough to be welding something this size that has to be going through a lot of vibrations and all around hell. So I purchased the TIG setup for my welder. Which meant I had to get an Argon tank. And regulator. And amperage pedal. $$$

    I started bending some more hoops:
    [IMG]

    and working on perfecting the mount design:
    [IMG] [IMG]
    TE250Guy, Scutler and Abby like this.
  3. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    Notching the main hoop (that's a level laying across to make sure my notch is at 90*):
    [IMG]

    Clamped to the front mounts for tacking:
    [IMG]

    This is the most time consuming part of the deal... These little guys have two notches taken at 90* to each other with an 8* offset:
    [IMG]

    And welded:
    [IMG]

    Straps welded across the back for mounting a Rotopax or whatever you want:
    [IMG]
    TE250Guy, Scutler and Abby like this.
  4. bluegopher Husqvarna
    AA Class

    Location:
    Woodland Park, CO
    Husqvarna Motorcycle:
    2013 TR650 Terra
    Looking good. Can't wait to bolt one of these things up and see if I can break it! ;)
  5. 268fords Husqvarna
    Pro Class

    Location:
    Powell, Wyoming
    Husqvarna Motorcycle:
    08' TE510'
    Other Motorcycles:
    Honda CRF 100, Kawasaki KLX 110
  6. chris1261 Husqvarna
    AA Class

    Location:
    North Jersey
    Husqvarna Motorcycle:
    2013 TR 650 Strada
    Looks great, RE. Have you thought about putting a 45* slash cut on the front mounts? Kind of like the ones where the upper engine mounts to the frame? It might carry the Oem look through.

    --Chris
  7. Lekolite Husqvarna
    A Class

    Location:
    Brevard, NC
    Husqvarna Motorcycle:
    TR 650 Strada
    Looks great! I really need to clean my shop so I can work in there again. Yours looks nice and organized.
  8. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    I was actually considering doing this to the inside of the rear mounts. But now you have me thinking... hmmm
    bluegopher likes this.
  9. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350

    It serves as motorcycle storage, welding shop, woodworking, reloading, craft room (for the wife), and as a storage unit. I have to try and keep it organized or it would consume everything.
  10. Lekolite Husqvarna
    A Class

    Location:
    Brevard, NC
    Husqvarna Motorcycle:
    TR 650 Strada
    Exactly what has happened to mine!
  11. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    And finally done:
    [IMG]
    [IMG]
    [IMG]
    PaulC, Hansi, TE250Guy and 5 others like this.
  12. mag00 Husqvarna
    Pro Class

    Location:
    Tucson
    Husqvarna Motorcycle:
    Terra, Strada
    Other Motorcycles:
    XR250 R1100RS CH50
    Finally, provisions for hooks. Why do others makers overlook this necessity? Have you any plans for the bottom side hooks? I find when I have a larger solid type cargo, I cannot hook to anything, unless I search under the rack, and sometimes have to hook to other parts of the bike, because the rack does not have hooks. A real pita.
    nev.. likes this.
  13. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    What do you mean by bottom side hooks? Can you post a pic of what you mean?
  14. msmith345 Husqvarna
    AA Class

    Location:
    Shawnee, KS
    Husqvarna Motorcycle:
    '12 WR250, '92 360, '80 390
    Other Motorcycles:
    '72 Yamaha R5, '17 SV650
    I think what he means is if you rotated those rings 90* straight down. That way if you have a larger load or a box on there (heck the rotopax might keep you from getting a good hook onto those) you can still get a bungee hooked easily.
    mag00 likes this.
  15. Highfive Husqvarna
    AA Class

    Husqvarna Motorcycle:
    TR650 Terra
    Other Motorcycles:
    Husaberg FE390, BMW F800GS
    Or just put a few vertical posts strategically around the bottom side......a place to hook a bungee when you need to stretch it a little more.

    Looking really good there, RE!

    HF
    RuggedExposure likes this.
  16. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350

    Ah, I understand now. There is plenty of room to still hook a bungee to these with the Rotopax or a large box on the top. There should be about 3/8" clearance between the bottom of a box and the hoops. I guess I could also put a ring on the side of the front mount to fasten too as well.
  17. msmith345 Husqvarna
    AA Class

    Location:
    Shawnee, KS
    Husqvarna Motorcycle:
    '12 WR250, '92 360, '80 390
    Other Motorcycles:
    '72 Yamaha R5, '17 SV650
    Nice, I couldn't tell how close those were to flush with the top of the rack. One thing we can all bet on is that an RE approved rack is gonna be more rugged and more versatile than anything else. It's looking dang good.

    Not sure if this was in one of the other threads, but are you planning on making new side racks to fit with this? I don't recall how you had yours fit before, but I thought you were using those bolts.
  18. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    This top rack will (should) work with other side racks that still allow you to use your factory top rack. Toura-tech makes one (http://www.touratech-usa.com/media/miONbr/09-412-5560-0.pdf) and I believe some other companies do as well. Depending on how much time I have down the road, I may make one that is integrated with a side rack system. Maybe.
    bluegopher likes this.
  19. mag00 Husqvarna
    Pro Class

    Location:
    Tucson
    Husqvarna Motorcycle:
    Terra, Strada
    Other Motorcycles:
    XR250 R1100RS CH50
    Even something like on this rack. Or Hooks. If you use like you have already, a nice strap would fish through and cinch well. These work well for the bungee hooks.

    honda90rack.jpg


    This photo is from a CL ad in Tucson. $375 for the honda 90.
  20. RuggedExposure Now with more rugged!

    Location:
    BFE
    Husqvarna Motorcycle:
    Terra 650
    Other Motorcycles:
    '08 Meanstreak 1600, '95 DR350
    Knocking out two more for FairbanksAK and Bluegopher:
    [IMG]
    [IMG]
    PaulC and bluegopher like this.