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Old 07-25-2012, 03:53 PM   #751
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Originally Posted by 100mpg View Post
I am not even going to give my thoughts on the color silver. Its your rack.
When you make my set of racks, could you paint them red?

I'm going to paint them like candy canes!
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Old 07-25-2012, 03:59 PM   #752
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I'm going to paint them like candy canes!
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Old 07-25-2012, 04:47 PM   #753
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Never mind caging the trash, build a bear trap!
Screw that!

Build him a minibike!!



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Old 07-25-2012, 04:55 PM   #754
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Screw that!

Build him a minibike!!




reminds me of that joke Robert shimmel used to tell his daughter when she asked him how the circus bear kept his feet on the pedals? He said, they nail them to the pedals!
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100mpg screwed with this post 07-26-2012 at 09:38 AM
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Old 07-26-2012, 10:57 AM   #755
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Screw that!

Build him a minibike!!



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Old 07-26-2012, 11:14 AM   #756
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The silver spraybombing is a pretty decent match for the frame.



I work up a quick sketch and get to it. Using more 5/8" x .065" wall DOM tube, I start working on the top rack.



Using some scrap, I eyeball the rack layout.



I bend some back-to-back 90s to serve as a grab bar. It should also protect the turn signals.



After about an hour or so, it starts taking shape.



Now I need to make the supports.





Front, center support made from 1/8" x 1" flat bar bent to shape.



This bolts to the factory fender support hole. I removed the OEM tool bag because it was pretty useless to me.



I make some tabs out of 1/8" x 1" flat bar to attach the rear rack to the lower support. Then I tack on some tube.





Then I use some more 1/8" x 1" flat bar for the front L & R supports. I attach to factory mounting points. I bend an offset in the flat bar using the vice and a hammer.



Getting there. Now I need to finish weld everything, and also weld in some mounting points for a top box, then do another rattlecan job.

I plan on making a long, narrow aluminum top box just big enough for my lunch bag.
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Old 07-26-2012, 12:02 PM   #757
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Very nice, though no surprise at all!

Jim
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Old 07-26-2012, 08:31 PM   #758
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Why all the space between the seat and rack?
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Old 07-26-2012, 08:42 PM   #759
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Very nice, though no surprise at all!

Jim

Thanks, Jim!
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Old 07-26-2012, 08:46 PM   #760
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Why all the space between the seat and rack?
I left room to overhang the top box. I plan on the box overhanging about 2" over the center rectangle on all sides.

All that will be seen of the rack will be the left, right, and rear grab rails.

If I remember correctly, the top box dimensions should be close to 14" W x 18" L. The depth will probably be around 8" or so.

Plus, I was thinking it will help in seat removal by not having the rack tight to the seat.

kirkster70 screwed with this post 07-26-2012 at 08:54 PM
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Old 07-26-2012, 09:27 PM   #761
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Figured you had a reason. Just too impatient, I guess.
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Old 07-26-2012, 09:41 PM   #762
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It never hurts to ask.
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Old 07-28-2012, 06:42 AM   #763
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All welds finished with the MIG. I weld in some 1" x 1/8" flat bar for the future top box mounting. I welded a 3/8" nut to the underside. I got a little sloppy with one of the hole centers. Oh well, the box will cover it and will likely be on the bike all the time.



Top rack tips the scales at 5lbs. The lower support is 3lbs. I used exactly 16' of tube combined. You can see where I had to scab in a small piece in the rack.

Now I need to dress up a couple of welds and break out the rattlecan. I'm pretty happy with the majority of the welds.


I just came off night shift and I'm supposed to be in bed. Maybe I'll have more to show tomorrow...

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Old 07-28-2012, 10:50 AM   #764
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Originally Posted by kirkster70 View Post
Top rack tips the scales at 5lbs. The lower support is 3lbs. I used exactly 16' of tube combined. You can see where I had to scab in a small piece in the rack.
Building out of 1/2" EMT would save you ~3.5lbs. I've found it plenty durable for racks and such.
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Old 07-28-2012, 04:31 PM   #765
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Building out of 1/2" EMT would save you ~3.5lbs. I've found it plenty durable for racks and such.
I think 1/2" EMT would be fine just for a small rack, but if I decide to actually take it in the woods and the bike takes a fall, that EMT won't hold up to that very well at all.

I wanted it to have more strength so that all three grab rails are actually functional for picking up the bike when down, or dragging it out of a mud hole if stuck. I don't think 1/2" EMT would fare very well for that purpose, either.
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