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#143494 - 11/07/18 03:24 PM XT250 Rack
Qwazert Offline
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Registered: 09/01/15
Posts: 317
Loc: Lower Rainland BC
It seems that all I do is build racks for these...

Unfortunately, I can't adapt the 225 version on my rear-rack...does anyone have any plans for the 250?
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http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650

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#143495 - 11/07/18 06:42 PM Re: XT250 Rack [Re: Qwazert]
Reggie Offline
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Registered: 07/25/05
Posts: 11639
Loc: Lancashire, England
Hi Qwazert,

I use the Happy Trails rear rack myself and I'm very happy with it.

I can send photo's to you if it helps?

Regards
_________________________
Reggie

Team Cabra, Brazilian XT225, Team Ukulele, Japan import XT225, a 250 to be named and loads of 2 stroke Kawasaki AR's!

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#143499 - 11/07/18 11:49 PM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
*****

Registered: 09/01/15
Posts: 317
Loc: Lower Rainland BC
Thanks Reggie, but I'm more of a DIY guy...thought maybe someone would have some suggestions.
I already have an idea of how this is going to play out, just looking for a different perspective.
_________________________
http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650

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#143500 - 11/08/18 02:10 AM Re: XT250 Rack [Re: Qwazert]
Reggie Offline
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Registered: 07/25/05
Posts: 11639
Loc: Lancashire, England
Hi Qwazert,

good luck and I look forward to seeing your project developing.

Regards
_________________________
Reggie

Team Cabra, Brazilian XT225, Team Ukulele, Japan import XT225, a 250 to be named and loads of 2 stroke Kawasaki AR's!

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#143510 - 11/09/18 07:54 PM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
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Registered: 09/01/15
Posts: 317
Loc: Lower Rainland BC
OK...looks like I'll be taking matters into my own hands.
Let's go!
(Each of the LINKs below the pic, takes you to a full-size version...sorry I don't know how to do it otherwise!)


First, I remove the grab bars to access a secure mounting point. Then I install some "stand-offs" to bring the mounting holes outside of the plastics.
The stand-offs are nothing more than 3/4" Aluminum dowel, drilled through and tapped to 8mm.
Then I insert a length of "Reddi-rod" and Loc-tite it into place:


LINK

The threaded rod goes in about " into the dowel.
Once installed onto the bike, it looks like this:


LINK

In this particular case, I will have to go back to the lathe and shorten the front dowels by about 3/8". My initial measurements were "rough" and I knew there was a chance that I would be going back to the tools to fine tune.
This shows the mounts on the muffler side, as well as how I reformed the plastics to accommodate.


LINK

Then I notched out the exhaust shield so that this future rack would fit, without rubbing on the shield and causing more noises!


LINK

What the left side looks like:


LINK

So now that I have mounting points, I can design a rack to fit. The rack frame will require some "geometry" in order to miss some components...it will probably be shaped something like this:


LINK

Crude, basic layout...finished product will be curvier and more appealing.
Instead of the " aluminum stock that I used last time, I will probably opt for the 3/16" or maybe even 1/8" risers. The one I made for the XT225 was overkill AFAIC.


...more to come.






Edited by Qwazert (11/09/18 08:10 PM)
_________________________
http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650

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#143511 - 11/09/18 09:18 PM Re: XT250 Rack [Re: Qwazert]
Reggie Offline
MR SEROW!
*****

Registered: 07/25/05
Posts: 11639
Loc: Lancashire, England
Hi Qwazert,

keep up the good work.

Regards
_________________________
Reggie

Team Cabra, Brazilian XT225, Team Ukulele, Japan import XT225, a 250 to be named and loads of 2 stroke Kawasaki AR's!

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#143513 - 11/10/18 01:36 AM Re: XT250 Rack [Re: Qwazert]
#brer15 Offline
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Registered: 10/03/16
Posts: 394
Loc: Atlanta,GA
Excellent work!
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2004 XT225 purchased new in October 2004 0 miles. Current miles over 27,000.

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#143519 - 11/10/18 03:56 PM Re: XT250 Rack [Re: Qwazert]
Muniac Offline


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Registered: 01/16/04
Posts: 5581
Loc: Montrose, CO
Rear racks are really handy. Nice addition to your bike.
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Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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#143520 - 11/10/18 06:20 PM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
*****

Registered: 09/01/15
Posts: 317
Loc: Lower Rainland BC
After *MANY* attempts, I came up with this semi-successful mock-up:


LINK

I say "semi-successful" because it obviously needs to be just a bit taller...which I will accomplish by extending the legs a wee bit and moving the mounting holes DOWN about ".
The legs are 60 from perpendicular and the rear deck of the rack is 30 from flat....two different angles, which makes things "interesting".

Painted, with a contrasting background:


LINK

Now, I'm going to take the dowels in and turn them down a bit...then maybe have a look at what sort of material to use to make these brackets.



Edited by Qwazert (11/10/18 06:21 PM)
_________________________
http://dr650rider.blogspot.ca/
2009 XT250, 2010 DR650

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#143522 - 11/11/18 01:10 AM Re: XT250 Rack [Re: Qwazert]
peejman Offline
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Registered: 06/03/13
Posts: 3021
Loc: East TN USA
Nice!
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This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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