On my last trip into the woods I was caryying to much crap on my back and it got to be a real pain after a couple of hours. So I decided I needed a better tail rack so I could get stuff off my back and onto the bike. There were some nice ones to purchase, but it was either wait 4 weeks or buy one for a DRZ/DR650 and modify it. Forget that, I got myself a little bit of steel and used the existing rear tail frame as the basis for a rack.
It’s not as pretty as the CNC cut aluminum ones, but it sure works great. When you build yours you can adjust to suit your needs. I put holes in the top so I could attach my wolfman toolkit.
To do this, you’ll need a welder, a grinder and a hacksaw. If you dont know how to weld, find a buddy, or hunt someone down in your neighbourhood. There are lots of people who have welders who LOVE projects like this. Really.
You will need the following material:
2′ of 3/4″ thin wall steel tubing
2′ of 1″ x 1/8″ steel flat bar
3′ of 1/4″ steel rod
6 pack of beer for the neighbour with the welder
Here is where it gets tricky, welding it together. Here is what I did:
- Make sure the ends of the tubes are 100% square
- Make sure the flat bars for either side are identical in shape
- Weld the tubes to the flat bar
- Do a test fit to the subframe – as mounted on the bike
- from here you might need to:
- splay the flat bars
- grind the angle
- twist the flat bars (especially for the rear piece)
- Once you have a nice dry fit, then weld it up and test the fit. You might want to just tack it together and test the fit first though.
Clean it up with a wire brush…