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#143535 - 11/12/18 06:02 PM Re: XT250 Rack [Re: Qwazert]
thinman Offline
Junior Member

Registered: 12/19/16
Posts: 46
Loc: Toronto, Ontario
It's a bit late for your project, but it's actually easier to design the rack attachment to fit in the notches that are already in the plastic for a rack.
http://www.xt225.com/forums/ubbthreads.php?ubb=showflat&Main=16105&Number=143270#Post143270


Edited by thinman (11/12/18 06:05 PM)
Edit Reason: added link

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#143553 - 11/16/18 06:34 AM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
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Registered: 09/01/15
Posts: 305
Loc: Lower Rainland BC
Moving along...
I lost the one mock-up that I was pleased with, so had to fabricate another.


LINK

The arm that sticks off to the right will be where the deck is...the arm will actually be a bit longer, but this is all the sheet plastic I had, so I made it work.

Fit it into place and it seems to be just fine, considering that I was working in the dark.
If necessary, I can lower the decking a bit by simply moving the mounting holes upwards...

I still need to get some stock to make the real thing....
_________________________
http://dr650rider.blogspot.ca/
2009 XT250
2010 DR650

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#143632 - 11/24/18 03:24 AM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
*****

Registered: 09/01/15
Posts: 305
Loc: Lower Rainland BC
Picked up some 3/16" aluminum yesterday...so I can carry on.

Transferred model to stock:


LINK

Then I cut out the brackets using two different methods.
One, I drilled for relief-cuts and the other I just cut freehand with an abrasive disc.


LINK

Cutting it directly was MUCH quicker, although the aluminum fouled the disc badly...but cut-off discs are cheaper than sweat.

Then, I marry the two pieces by bolting them together in strategically-placed holes. This way, I will produce exact copies.
These holes will be used when the rack is assembled.


LINK

Shaping takes time....a LOT of time.


LINK

But eventually (a few hours later), I end up with two matching brackets.


LINK

...and now I am ready to drill mounting holes.


LINK


...to be continued.


Edited by Qwazert (11/24/18 03:25 AM)
_________________________
http://dr650rider.blogspot.ca/
2009 XT250
2010 DR650

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#143634 - 11/24/18 07:39 PM Re: XT250 Rack [Re: Qwazert]
Muniac Offline


Platinum Member
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Registered: 01/16/04
Posts: 5531
Loc: Montrose, CO
Interesting project. Keep it evolving and please keep providing your continued updates as progress is made.

It is interesting over the past 14 years to see tail racks evolve. Now to include both the XT225 & XT250 models. Coupled with a tank/tail bag they are very useful to have.
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Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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#143635 - 11/24/18 09:09 PM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
*****

Registered: 09/01/15
Posts: 305
Loc: Lower Rainland BC
Added some aluminum angle to the top edge of each bracket.
Then, I was able to mate the brackets to a piece of plywood I had used for another rack on another bike at some other time....


LINK


This shows how I avoided the exhaust shield on the right-hand side.


LINK


Prototype completed...this will do "for now". I still need to add some reinforcement at the front and back by means of some aluminum dowel, but since the holes are pre-drilled (from the above shaping process) I can do this whenever I can get some lathe time.

All I really needed "for now", was a carrier for my lunchbox to get to and from work.
With the holiday season approaching, I don't know how much time I'll be able to devote to finishing this off.
I hope to make a decent deck for this rack and will probably paint the whole thing a nice gloss black.
I already painted the right side bracket....before being complete, just to see how it would work.

...a project for 2019.

*


Edited by Qwazert (11/24/18 09:38 PM)
_________________________
http://dr650rider.blogspot.ca/
2009 XT250
2010 DR650

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#143650 - 11/27/18 10:31 AM Re: XT250 Rack [Re: Qwazert]
Paul49 Offline
Platinum Member
*****

Registered: 07/22/11
Posts: 1623
Loc: High Peak, UK
Similar job to my diy effort. I used a couple of angle strips to the side plates then fitted an ally top plate using st/st 4mm pop rivets.

_________________________
1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, Tiger 800 XRx.

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#143678 - 12/01/18 10:25 PM Re: XT250 Rack [Re: Qwazert]
Qwazert Offline
Member L3
*****

Registered: 09/01/15
Posts: 305
Loc: Lower Rainland BC
80% complete now...
Added aluminum dowels fore and aft for rigidity.


LINK

Rear dowel is slightly larger than front, because I may need to use it as a grab bar...


All I need now is some sort of deck...considering using aluminum slats for that as well.
AL can be drilled and tapped for various bins and carrying contraptions.


LINK


LINK


I am pleased with the outcome... grin


Edited by Qwazert (12/01/18 10:26 PM)
_________________________
http://dr650rider.blogspot.ca/
2009 XT250
2010 DR650

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#143679 - 12/02/18 02:54 AM Re: XT250 Rack [Re: Qwazert]
Muniac Offline


Platinum Member
*****

Registered: 01/16/04
Posts: 5531
Loc: Montrose, CO
Looks like it's turning out nicely. We have used our rear racks for some 15 years now. To carry tools, tow straps, docs, extra oil, tube, spark plug, etc. Enjoy the fruits of your labor and ride safely.

A good coating for this type of gear is Line-X if you have one near you.
_________________________
Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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#143680 - 12/02/18 03:45 AM Re: XT250 Rack [Re: Qwazert]
peejman Offline
Platinum Member
*****

Registered: 06/03/13
Posts: 2981
Loc: East TN USA
Looks good!
_________________________
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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