How I built my homemade rear rack... - Kawasaki KLR 650 Forum
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post #1 of 14 Old 05-28-2011, 01:09 PM Thread Starter
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Join Date: Apr 2011
Location: Vallejo, CA
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Thumbs up How I built my homemade rear rack...

When I was designing my rack for the four week trip I just returned from around the Southwest, I really appreciated other people's photos and input online. So, I thought I would put some photos up here in case they can help anybody else.

This is my first motorcycle, I bought it just a few weeks before the trip. I had never even ridden on a freeway, nor anywhere fully loaded before I departed on the trip. Keep that in mind when criticizing my design. The rack performed exceptionally well on and off road. The stout ammo cans even protected the bike when I layed it down in the soft Utah sand (I was/am a total newb offroad). Also, I am no welder. I just took a beginning welding class at my school so I could make this, and the rack was my first experience using a TIG welder, so it's pretty sloppy. I just tried to overbuild it to compensate for my poor welding job.

Total Cost:
30 feet of square steel tubing: $20
ammo cans: $30/each
hardware: $10

Last edited by Tom Schmitz; 03-15-2012 at 04:57 PM.
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post #2 of 14 Old 05-28-2011, 03:10 PM
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A KLRista has been born!

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Oh, and I ran two quarts of hot oil through before filling her up cause I'm anal.
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post #3 of 14 Old 05-28-2011, 03:51 PM
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Way to go Mr. Miyagi. Looks like you did a fine job on the rack and you have the satisfaction of having done it yourself.

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #4 of 14 Old 05-28-2011, 04:30 PM
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Too many apologies in there! Don't apologise for your riding skills,;we all started somewhere and don't do your fabrication work an injustice - be proud of what you did. I think it's a fine testament to your skills for your rack to have lasted an on/off road trip with no issues.

I had a professionally manufactured Renthal rack that I certainly can't speak as highly of! What a waste of money that was! Grrr!

Anyway, congratulations on taking the bull by the horns and getting the job done. Particularily like the relocated indicators - nice job!
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post #5 of 14 Old 05-28-2011, 05:02 PM Thread Starter
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You're right, UK...I always brace myself for insults when posting anything online, but I forgot that the KLR community is not as harsh a critic as the rest of the web.

The indicators were a struggle. I didn't like the long shaft that they were attached to, made them look awkward anywhere I put them. So I cut it off, drilled a hole in the back of the housing, and welded tabs onto the rack to support them. I'm really pleased with the way they turned out.

The spare indicators that I had, I put at the bottom of the rack and wired them into the license place light so they are always on when the ignition is on. Those, coupled with the reflective tape on the ammo cans, make me more visible at night, I reckon.
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post #6 of 14 Old 05-29-2011, 01:35 AM
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Excellent job!! I like that better than the set up I paid much more for.
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post #7 of 14 Old 03-19-2012, 02:12 PM
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Mr. Miyagi, Very nice! I have a rack sold by the 'company that must not be named' (Named after an old now-defunct American car maker) - they are flimsy to say the least. A couple not-so-rough lay downs and they tend to warp. Yours are solid! I may use your methods to try crafting something better. The junk I have likely won't hold the heavier ammo cans well.
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post #8 of 14 Old 03-20-2012, 02:11 PM
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Yup, Mr Miyagi... good on you sir.

Looks strong enough to thwart a couple of tip overs. and, it looks sharp all decked out.

be always thankful for the things we have, people we know, and for our life here on earth.
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post #9 of 14 Old 03-25-2012, 08:05 PM
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Nice Work

up grade's 2008 green,
Cee Baily tinted wind shield, studibaker skid plate, one inch length added to shifter, highway pegs, steel pegs,Jardine pipe, trunk, head light rock gard, , 12 volt power outlet, 16 tooth front sprocket, Progressive front springs, studibaker master cylender guard, PVC mod,Doo Hickey, one wheel offroad trailer, night vision ammo cans for side bags my oun tank gards.
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post #10 of 14 Old 03-26-2012, 03:33 AM
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"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

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Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
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