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Old 01-22-2013, 04:14 PM   #1471
kirkster70 OP
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Pannier rack hoops bent out of 5/8" O.D. DOM tube.



250' roll of bulb gasket shows up for panniers.



7/16" round bar cut in 1" lengths...



...to join the hoop halves. I leave a gap the width of the tube wall for the weld bead to lie in.



After full weld-up, butt welds are ground flush with the surrounding tube.



Now then - let's figure out how to attach them to the bike. I cut some 3/4" strut and lay that across the rear rack. Now I have a reference point for measuring and alignment purposes.



One I determine the mounting points, the hoop and the strut combine to allow me to eyeball mounting options.



I like starting with the hard side first. The opposite side is usually a snap after dimensions are figured for the ex. side. Plus, I will be able to figure out the bag relief and match the right sides width for symmetry. I also need to be mindful to leave a little bit of an air gap to combat heat from the pipe.

After dinner break is over. Back to the garage to figure out some more... Until next time.
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Old 01-22-2013, 05:16 PM   #1472
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Originally Posted by kirkster70 View Post
I got to thinking - with a 6" flange, isn't that an "H" beam? Make sure your trolley will adjust that wide.


That's one of the reasons the beam could end up being the base legs. That, and I really want a longer span between the legs. So I think I will find or buy a longer I beam.
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Old 01-22-2013, 06:39 PM   #1473
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I have an idea. 1 1/2" x 3/16" flat bar cut to size.



More 3/16" flat bar cut down to 1" x 3" pieces.



Turn on some Michael Jackson and just beat it.





And then beat it some more.



A couple tacks on the backside to see if this will work. The main flat bar is bent to match the contour of the tail section. I'm not very familiar with the GS, but I can only guess that these ears are for factory cases. Let's use 'em!



Now I will fabricate a piece to attach this to the screw sticking out. Then I can attach the hoop to this bracket with more DOM tube.

That should work just fine. Hopefully more to see tomorrow...
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Old 01-22-2013, 09:24 PM   #1474
JimVonBaden
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Looking good Kirk. Yes, those are the factory bag mounts. Keeping the bags parallel with the seat and frame will be easy that way.

Jim
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Old 01-23-2013, 02:03 AM   #1475
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Looking good Kirk. Yes, those are the factory bag mounts. Keeping the bags parallel with the seat and frame will be easy that way.

Jim
Good! I'm glad you like what you're seeing. I want to be ready to drop off everything to the powdercoater by Thursday afternoon or sooner.
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Old 01-23-2013, 11:32 AM   #1476
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Bracket with a stand-off made from 3/16" flat bar and 5/8" DOM tube...



...to go here.



5/8" DOM bent and cut...



...to tie the stand-off to the main bracket. Everything is fully welded front and back. Exterior welds and corners dressed up with a flap wheel. Now I need to duplicate this on the other side.
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Old 01-23-2013, 06:36 PM   #1477
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Still pluggin' away at the GS rack...







Notching some tube...







This side kicked my butt today! Hopefully the other side will go a little better tomorrow.
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Old 01-23-2013, 09:10 PM   #1478
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Looking good Kirk!

The right side should definitely be easier.

Jim
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Old 01-24-2013, 03:31 PM   #1479
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Looking good Kirk!

The right side should definitely be easier.

Jim
Thanks, Jim!

It was a little easier. Not much, though. Pics incoming...
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Old 01-24-2013, 03:39 PM   #1480
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Racks complete. I remount them after welding to make sure there are no warpage issues.





Lower mounts and hinges fabricated. Everything is QCed for the maiden voyage to the powdercoater in the morning. I also trimmed 3/8" off the bag's flange. I purposely overbent it because I wasn't sure how deep the gasket was going to be when I got started. I just sliced it off with an aluminum cutting wheel.

Welds on gasket mating surfaces are ground level with a flap wheel. This was a workout!!

I have some reading material to look at while everything is getting coated...
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Old 01-24-2013, 03:42 PM   #1481
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Awesome!

Jim
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Old 01-24-2013, 04:06 PM   #1482
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I have some reading material to look at while everything is getting coated...


Check out Lincoln's Literature offerings as well. Some good stuff in there, and best of all, it's FREE! (it's under the Support tab on the website)
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Old 01-24-2013, 10:35 PM   #1483
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Genius!

(And that ole JimVB is a sly one ain't he...I thought that was his GS in the very first pictures, but the subsequent posts gave it away.)

Yer a lucky man, Jim!
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Old 01-25-2013, 07:24 AM   #1484
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Yes I am! Kirk is doing a great job!

Jim
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Old 01-25-2013, 03:52 PM   #1485
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Thanks, guys! I'm very excited to see everything after powder.

The people who own the powdercoating business are extremely nice.

I asked them how in the world a coating business could be 15 min from my house w/o knowing about it? They told me that in the past they were exclusive to large businesses and mil spec coatings for Uncle Sam. (There were 2 H1 Alpha Hummers in the shop when I went there today) They have only recently opened the doors for everyone else.

The only reason I found out about them in the first place was having a mutual friend. That worked out great!

So now it's a waiting game, but I'm confident they will do a great job. They were trying to talk me into powdering the Tundra bumper. Maybe in the spring.
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