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: So I got down to working on a design for a heavy duty one in my free time: I started with making the bend of the main hoop: I fiddled around with the design and angles and ended up with this: 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:
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: 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: and working on perfecting the mount design:
Notching the main hoop (that's a level laying across to make sure my notch is at 90*): Clamped to the front mounts for tacking: 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: And welded: Straps welded across the back for mounting a Rotopax or whatever you want:
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
Looks great! I really need to clean my shop so I can work in there again. Yours looks nice and organized.
I was actually considering doing this to the inside of the rear mounts. But now you have me thinking... hmmm
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.
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.
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.
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
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.
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.
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.
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. This photo is from a CL ad in Tucson. $375 for the honda 90.