Started on some side racks - Kawasaki KLR 650 Forum
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post #1 of 20 Old 07-06-2012, 10:08 PM Thread Starter
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Started on some side racks

I started building side racks tonight. I think I'm gonna do 40mm ammo cases on the sides and a pelican case on the back rack.

Work in progress:



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post #2 of 20 Old 07-07-2012, 02:11 AM
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Very nice.

FWIW:
1) I bought 20 mm ammo cans because they were slightly larger whilst being approximately the same weight. I've modified the first one, now it has hinges and a lock. It is also about 4 lbs lighter than when I first got it.
2) My happy trails set are mounted higher than yours. (NOTE: Not intended as Higher=better, just a general observation)
3) I found an ebay retailer that sells them for about 150 after I paid HT 260. klr650reviews.com recommended this ebay seller to me. :|
4) These are looking good.

Post pictures when you've got em done if you don't mind.

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

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post #3 of 20 Old 07-07-2012, 02:20 AM
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Also, I don't know if you ride two up or anything, but the happy trails ones make the rear footpeg somewhat uncomfortable



Not the greatest angle, but you can see that there is a bar that protrudes about an inch into the passenger footpeg area. This may not be a big deal to you, but I think you could bend them so they fit on the back side of the footpeg.

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

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post #4 of 20 Old 07-07-2012, 06:30 AM Thread Starter
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After thinking about it I'm gonna raise it up a bit. I think I'm a little low right now. I don't ride 2 up on this bike which is good because I'm planning on using the same mounting point on mine as the happy trails rack.


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post #5 of 20 Old 07-07-2012, 06:00 PM Thread Starter
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Update and revision:




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post #6 of 20 Old 07-07-2012, 06:21 PM
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I wish I had welding skills like you. Perhaps I can just live vicariously through you?

An advantage I thought of with the higher mounted design is that in the event of a tip over, less leverage will be acting on the bar...less likely to bend.

Also, I like the hexagon polygon thing you've got there. Makes the shape a little more interesting. Is there a functional reason for that?

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

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post #7 of 20 Old 07-07-2012, 06:26 PM Thread Starter
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No reason for the shape. It's just less boring than a square. Lol. I still have one more support to add to the top and then a bar going from side to side to stiffen everything up. If you're near the Denver area in always up for helping a fellow biker.




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post #8 of 20 Old 07-07-2012, 06:29 PM
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I'm with you on that. Plus, if you part out the bike, you can sell it to an art gallery as "Abstract art."

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

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post #9 of 20 Old 07-08-2012, 11:42 AM Thread Starter
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Progress. Almost done. Just need to clean up and paint. I relocated the license plate bracket to the cross member. I'm picking ammo cans later today.




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post #10 of 20 Old 07-08-2012, 01:07 PM
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Wow....excellent job...What welding tools are you using? The spots are clean. Do you have a trade in welding?

Again great job...
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