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Rear rack #128673 10/08/15 05:09 PM
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Qwazert Offline OP
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This is a question to anyone who has built a rear rack from a single piece of sheet metal...

What is the distance between the two bends, that is to say, how WIDE is the rack, so that it fits into the grab-handle mounting holes?


http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650
Re: Rear rack [Re: Qwazert] #128679 10/09/15 11:24 PM
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Doc250 Offline
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Hi Qwazert.

Unless your an accomplished sheet metal worker and know the formulas for doing accurate bending it will be a nightmare making a rack from a single piece of metal.

The easiest way is to make the two side pieces separately and then attach the top using some angle iron or similar brackets.

Here is a link to my rack build on my 250...


http://www.xt225.com/forums/ubbthreads.php?ubb=showflat&Main=3769&Number=29518#Post29518

Post some pics of your build.


Roads? Where we're going we don't need roads!
Re: Rear rack [Re: Qwazert] #128681 10/10/15 10:44 AM
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Paul49 Offline
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I was a metal basher before I got idle & took a sit down job. I would have made mine from a single sheet to save all the drilling & fastening, if only I had access to a folder.
Seeing as I didn't I made mine similar to Doc's, made 2 of them now for the XT (stolen) & the current Serow. Pics of mine are on here somewhere like Doc's.

If you're going that route, the fold lines need to be 9" apart then the top section will be 9" plus the radius'd corners eg 9,1/4" overall.
If you don't have access to a decent folder, it's unlikely to turn out very good.
You'd still need to use Doc's cad method to make templates to mark out the side sections after you've folded it.

Good luck & post up the results.

This was my effort on the 2005XT, they are different, see bend at front of grab rail for Brazil model.


This is my 1995 Serow rack, I got lazy & assembled it with 4mm Stainless rivets.



Last edited by Paul49; 10/10/15 11:12 AM. Reason: found pics

Current: 1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, 2016 Tiger 800 XRx.
Re: Rear rack [Re: Qwazert] #128685 10/10/15 09:02 PM
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Qwazert Offline OP
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I like your finished products.
I'm not planning to build one out of a single piece (although some have) but I just wanted to get a dimension so that I could pre-fab the top plate.
I am planning to make mine in the same manner as the Load Lord that is advertised, but I am having some difficulties.
This is the pattern that I am using:


http://i82.photobucket.com/albums/j275/q...%20Rack2%20.jpg


(Anybody is welcome to copy it...make your own tweaks and variations as you see fit)
And I am having a hard time making the cuts because I am using ¼" aluminum. It's a very slow process when you don't have access to a milling machine or CNC...and being a bit of a perfectionist (time will tell) I like to have the fit and finish EXACTLY to my liking...


Last edited by Qwazert; 10/10/15 09:06 PM.

http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650
Re: Rear rack [Re: Qwazert] #128686 10/10/15 11:18 PM
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Qwazert Offline OP
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Here is one UNfinished bracket, rough-cut...what a chore!



...still have to make another, and then shape them in unison!

Last edited by Qwazert; 10/10/15 11:18 PM.

http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650
Re: Rear rack [Re: Qwazert] #128687 10/11/15 01:19 AM
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Az4x4 Offline
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Looks good so far. Let us know how things go as you get deeper into the project..


..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: Rear rack [Re: Qwazert] #128708 10/11/15 09:14 PM
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Paul49 Offline
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Ayup Qwazert,

How thick is that metal? is it ally? It don't look very strong & you got some nasty stress points in it. Don't mean to be critical, just trying to help. Don't want it snapping after you put a lot of work into it.


Current: 1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, 2016 Tiger 800 XRx.
Re: Rear rack [Re: Paul49] #128721 10/12/15 12:45 AM
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Qwazert Offline OP
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Originally Posted By: Paul49
Ayup Qwazert,

How thick is that metal? is it ally? It don't look very strong & you got some nasty stress points in it. Don't mean to be critical, just trying to help. Don't want it snapping after you put a lot of work into it.

Yes, it IS aluminum...¼" thick aluminum.
The Load Lord uses 1/8" aluminum for its side rails...I just wanted to go a bit stronger.
I can't see any "stress points"...can you elaborate?


Last edited by Qwazert; 10/12/15 12:51 AM.

http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650
Re: Rear rack [Re: Qwazert] #128722 10/12/15 12:50 AM
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Qwazert Offline OP
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Using nothing but power tools and hand tools, I've finally got BOTH brackets completed.
Now, I've drilled out the mounting holes because it's fairly critical that both side sit at the right height,etc.



From this point, I will use more hand tools to match the two shapes.



Bolting it together will "Siamese" the brackets for further shaping...
I'm liking the progress so far...even though it was a real chore!

The angle along the front of the bracket, matches and runs parallel to the slope on the lower edge of the seat.


http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650
Re: Rear rack [Re: Qwazert] #128725 10/12/15 07:48 AM
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Paul49 Offline
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Ok m8, 1/4" is much better, looked like 1/8" in the first pic. !/8" would be fine with more metal left in. I made mine from 1/8" & can lift the bike up with it.
The sharper the change in direction, makes for a weaker stress point. A larger radius leaves it a lot stronger.


Current: 1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, 2016 Tiger 800 XRx.
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