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Discussion Starter #1 (Edited)
I have a couple 40mm cans i want to use as side panniers and I was trying to find a good side rack to mount them with. Right now it's between the Happy Trail SU rack and the SW-MOTECH quick removable ones though I'm leaning SW due to the quick removable part.

20 lbs a can is making me wonder about rack strength as well as if they would be too heavy for the KLR. Money is an issue though and I already have the cans so unless there is some insurmountable problems with 40mm cans I guess I'll make due.

Just wondering if anyone has some experience or opinions to share.
 

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Discussion Starter #3
Aha that's what those are. I was noticing that nothing looked like the racks I photoed on other bikes with cans.
 

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I was talking with Tim of Happy Trails when we were in Moab. They are going to be coming out with a new rack system soon; I saw a prototype on a DRZ400. It looks to be very heavy duty and will have a quick-release frame (that locks into the rack) that you can bolt up to virtually any hard case.

It will likely be more spendy than the Pack Rats, but if you're not in a giant hurry it might be worth waiting to take a look at.

I have no idea on the release date, but am waiting with bated breath...

(Hurry up, Tim)

T
 

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Build custom racks……
This may be my next DIY project. Just got done with my seat scoop(which I took step by step pics of), next is raising the bike 2" and then I think I may start working on a rack. Anyone got links for a cheap ghetto way to do this? It's not that I can't afford the store bought ones, I just like to feel like I can do it on my own, or with tech help from those who have walked this path before.

prethanks, for anyone with words of wisdom.
 

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Discussion Starter #8
I was talking with Tim of Happy Trails ... quick-release frame ...
T
I'm trying to get my cases on this month so I think I'll probably go with traders suggestion. I do like the quick release idea, but i think I'm going to try and re-purpose some auto hood pins instead of buying a system. I need to make sure it's tight enough to not rattle though.
 

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You can build your own racks. Copy the pelican style and make your tubing out of square steel 3/4"stock . I used 1/2" which seemed adequate at the time. Since then, I've learned better. Keep in mind the passenger pegs need to be clear if you are going to double up. Mine are for this reason, but you can decide. The weight isn't an issue at all if you stick to pavement. You have more than enough pep to do what you want. Send me an email if you want the whole skinny. I like Tom's Idea, but like you, I'm not up to my ears in Bread right at this moment.
 

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Discussion Starter #10
I'd love to try and make my own rack and learn in the process, but I have no access to the tools required and a budget that would only allow one shot. I really think that buying an already assembled rack is the best option for me.
 

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yes, I did think of this after I had clicked the post button. Sorry for that. Welding isn't easy if you haven't done it before. Make sure to get one that is tough. You will want the stability of this frame to support the bike in event of tipping. The boxes are very tough and will do marvelous for this reason.
 
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