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Old 01-08-2012, 08:20 AM   #1
zoomzu OP
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Side Racks For My KLR650

Since I can afford time more than I can money, and I need side racks.

This just doesn't cut it. So I bought some pipe, 3/8" schedule 40

and recruited a friend. I'm going to build my own racks. After all I am a KLR owner.

I start to cut metal for the mounting brackets.

Blane takes over that task. Radius the brakets and drills them out.



While that is getting done I start to bend the ovals. Well..... It's almost an oval


Together we bend the mounting pipes, and get the ovals tacked in to place.



So for the right side I get help with bending the oval. This side turned out a bit better. Made the mounting pipes, welded that together. Bent up some 3/16" rod for mounting/strapping points.


After Blane's meticulous cleaning of slag, and a bit of acetone. they are ready for powder.



Out of the oven and onto the bike.




Even Kurmit The Frog is amazed how well they turned out.


Thanks Blane AKA "therivermonster" if I did them myself, they'd be jacked. And I know I wrench's would fly without it. Sorry you couldn't make it over Erik, maybe on the crash bar build.
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Old 01-08-2012, 08:27 AM   #2
byways
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Get ready for a flood of purchase orders ...

Can the right-side cover be removed without removing the rack from that side, to service the air filter ... the bane of riding a KLR on dusty Western roads? I gave up trying to find a set that would let me pull the filter without removing the rack, as I must do at least twice a day when traveling off-pavement.

byways screwed with this post 01-08-2012 at 08:54 AM
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Old 01-08-2012, 08:34 AM   #3
adventurerik
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wow they look great !
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Old 01-08-2012, 09:16 AM   #4
Wolfgang55
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Good job.

Don't forget to post PIX of the planned load mounted up for traveling.....everyone likes a dressed up KLR
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Old 01-08-2012, 09:21 AM   #5
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Yea Man. How much would you charge?
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Old 01-08-2012, 03:27 PM   #6
zoomzu OP
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Eek

Quote:
Originally Posted by byways View Post
Get ready for a flood of purchase orders ...

Can the right-side cover be removed without removing the rack from that side, to service the air filter ... the bane of riding a KLR on dusty Western roads? I gave up trying to find a set that would let me pull the filter without removing the rack, as I must do at least twice a day when traveling off-pavement.

I didn't even think about the side cover. I'll have to check.
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Old 01-08-2012, 03:35 PM   #7
byways
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Old 01-08-2012, 09:05 PM   #8
zoomzu OP
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Quote:
Originally Posted by byways View Post
...

Can the right-side cover be removed without removing the rack from that side, to service the air filter ....


I am able to get the side cover off.
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Old 01-08-2012, 09:13 PM   #9
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Quote:
Originally Posted by Dave2 View Post
Yea Man. How much would you charge?
Me going in to production.... I don't think that would happen. Besides I might have a legal problem with the design.
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Old 01-09-2012, 05:52 AM   #10
byways
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Quote:
Originally Posted by zoomzu View Post
I am able to get the side cover off.
Fantastic! That's a big deal. If you ever decide to make them for sale, tout that fact. I just bought the eBay racks, and I'm not looking forward to undoing one 2 or 3 times a day during long dirt rides.
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Old 01-09-2012, 07:01 AM   #11
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Quote:
Originally Posted by byways View Post
Get ready for a flood of purchase orders ...

Can the right-side cover be removed without removing the rack from that side, to service the air filter ... the bane of riding a KLR on dusty Western roads? I gave up trying to find a set that would let me pull the filter without removing the rack, as I must do at least twice a day when traveling off-pavement.
I've got SW motechs and I can get my side panels off without removing the racks, and after that the air filter is a snap. I don't think the racks have been off of my bike since 2008.
Nice work on the racks.
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Old 01-13-2012, 08:29 AM   #12
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KLR Harley

In the process of making these racks Mike had also started on some, ahhum, highway pegs for his KLR.
That was the motivation for the following versus.


KLR Harley

by Blane Nelson
for Mike Z


I came upon a man I know, who seemed beside himself.
He spied a piece of metal there, and pulled it off the shelf.


With tools in hand Z cut and drilled and shaped those highway pegs.
Bolted there across crash guard, he now could stretch his legs.


He pulled his textile jacket off and strapped his leather on.
Taking care to mind chin strap, his bucket he did don.


Button down the starter cranked, that thumper roared and bellowed.
All dressed up they headed out, a gang of pirate fellow.


Cruising then on down the street, eyes wide they looked at Z.
There he went, the man in black, on his KLR Harley.


The pirate that rode next to Z was hanging from his bars.
Swinging like an ape in tree and scaring all the cars.


Z realized that this was wrong and punched on into fifth.
He had to get away from them, but KLRs aren't quick!


So home he went to log back on to ADV.com.
To lead his life from dark to light, to learn what’s right from wrong.


Out to his bike he raced, wrench flailing all around.
He madly wrenched those highway pegs and threw them to the ground.


Off with his leather jacket. On with his textile suit.
He pulled those Harley sneakers off and donned a proper boot.


Now stopped along the highway, he peered with a deep stare.
Down a dirt road did he spy a place to catch some air.


Throttle up, clutch out, tire spins, mud fleeing from his tread.
And as that KLR took flight, came clearing to his head.


So welcome back to our friend, Z. He’s come in from the night.
We owe it to our ADV, and now he is alright.
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Old 01-13-2012, 11:56 AM   #13
DirtyDog
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Quote:
Originally Posted by therivermonster View Post
In the process of making these racks Mike had also started on some, ahhum, highway pegs for his KLR.
That was the motivation for the following versus.


KLR Harley

by Blane Nelson
for Mike Z


I came upon a man I know, who seemed beside himself.
He spied a piece of metal there, and pulled it off the shelf.


With tools in hand Z cut and drilled and shaped those highway pegs.
Bolted there across crash guard, he now could stretch his legs.


He pulled his textile jacket off and strapped his leather on.
Taking care to mind chin strap, his bucket he did don.


Button down the starter cranked, that thumper roared and bellowed.
All dressed up they headed out, a gang of pirate fellow.


Cruising then on down the street, eyes wide they looked at Z.
There he went, the man in black, on his KLR Harley.


The pirate that rode next to Z was hanging from his bars.
Swinging like an ape in tree and scaring all the cars.


Z realized that this was wrong and punched on into fifth.
He had to get away from them, but KLRs aren't quick!


So home he went to log back on to ADV.com.
To lead his life from dark to light, to learn what’s right from wrong.


Out to his bike he raced, wrench flailing all around.
He madly wrenched those highway pegs and threw them to the ground.


Off with his leather jacket. On with his textile suit.
He pulled those Harley sneakers off and donned a proper boot.


Now stopped along the highway, he peered with a deep stare.
Down a dirt road did he spy a place to catch some air.


Throttle up, clutch out, tire spins, mud fleeing from his tread.
And as that KLR took flight, came clearing to his head.


So welcome back to our friend, Z. He’s come in from the night.

We owe it to our ADV, and now he is alright.
Fucking priceless.
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Old 01-13-2012, 12:55 PM   #14
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Nice job.
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Old 01-13-2012, 03:09 PM   #15
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I wish I could make something like that! I did just wire a welder plug in my garage! Now I just need, uh...
  1. a welder
  2. the ability to weld
  3. piping
  4. a pipe bender
  5. the ability to bend pipe
  6. powdercoating stuff
  7. the ability to powdercoat


Also, the Happy Trails SU racks allow you to remove the side panels and air filter without removing the racks.
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