Sin City Stan
05-01-2011, 04:23 PM
This is a follow up from a previous post of mine on how to make a trunk rack. Some asked for pictures so I took allot.
Previously I made a cardboard template. Took it to work and transferred the dimensions to Auto Cad. I printed full size drawings and attached to the 11 Ga. steel with rubber cement.
Side Rails
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Template1.jpg
Aluminum Top Plate
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Template2.jpg
I center punched all of the holes and drilled them. Then used a jig saw to cut the side rails out.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Cutout1.jpg
Peeled of the paper.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Cutout2.jpg
Rubbed off the glue and checked the fit.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RightRail2.jpg
Had interference with the chrome trim and had to grind a bit off between the shock mount and first bolt hole. Then I used the metal rail to modify the left side rail. I blame this on the cardboard template that was not rigid enough.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Rework-1.jpg
Modified Right side rail.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RightRail2.jpg
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RightRail3.jpg
Left side rail. We have a problem Houston. http://s2.images.proboards.com/shocked.gif This is the first time I really looked at the left side. Silly me thought they were the same. But no, the left side shock sticks out 3/4" further than the right hand shock. ??? More on this further down.
Positioning the top plate
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RackRight1.jpg
The bolts shown will actually bolt through the trunk, top plate and side angles.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RackRear.jpg
Now you can see the left side rail has been shortened. Having no way to produce compound bends I elected to cut the shock mount off. There are still four points of attachment to the frame or the sissy bar casting which also attaches to the frame.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RackLeft.jpg
The trunk will be 13" tall. About an inch shorter than the existing backrest.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/13Inches.jpg
The trunk is 23" wide and will overhang the bracket 4 1/4" on each side. And yes, the saddle bags will clear the trunk by 3/4" when opened. http://s2.images.proboards.com/grin.gif
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/23Inches.jpg
The finished rack.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Rack.jpg
Until I get the trunk and remove the sissy bar I cannot determine exactly how far the trunk will extend past the end of the bike but I'm guessing 2-4".
I still have to disassemble the rack and take a belt sander to all of the edges. I also have to buy/make spacers for all of the frame bolts to match the recess in the chrome trim. I used washers for the fitting. Not sure if I will just paint it black or match the lower bike color.
Specifics
Side rails: 1/8" Steel
Top Plate: 1/8" Aluminum
Support angle: 1"x1"x 1/8"
Weight: 7.4 lbs. (calculated)
Time: About 6 hours including putting the bike back together.
Rigidity: I literally sat on the rack with no discernible movement other than the shocks compressing. This was never really a worry as my chief concern was horizontal movement of which there was none as I applied what I guessed to be about 50 lbs. of side force to the end of the rack.
So that's it. I have a rack that lets me keep the grab rails and provides a lower mounting point for the trunk.
Previously I made a cardboard template. Took it to work and transferred the dimensions to Auto Cad. I printed full size drawings and attached to the 11 Ga. steel with rubber cement.
Side Rails
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Template1.jpg
Aluminum Top Plate
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Template2.jpg
I center punched all of the holes and drilled them. Then used a jig saw to cut the side rails out.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Cutout1.jpg
Peeled of the paper.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Cutout2.jpg
Rubbed off the glue and checked the fit.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RightRail2.jpg
Had interference with the chrome trim and had to grind a bit off between the shock mount and first bolt hole. Then I used the metal rail to modify the left side rail. I blame this on the cardboard template that was not rigid enough.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Rework-1.jpg
Modified Right side rail.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RightRail2.jpg
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RightRail3.jpg
Left side rail. We have a problem Houston. http://s2.images.proboards.com/shocked.gif This is the first time I really looked at the left side. Silly me thought they were the same. But no, the left side shock sticks out 3/4" further than the right hand shock. ??? More on this further down.
Positioning the top plate
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RackRight1.jpg
The bolts shown will actually bolt through the trunk, top plate and side angles.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RackRear.jpg
Now you can see the left side rail has been shortened. Having no way to produce compound bends I elected to cut the shock mount off. There are still four points of attachment to the frame or the sissy bar casting which also attaches to the frame.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/RackLeft.jpg
The trunk will be 13" tall. About an inch shorter than the existing backrest.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/13Inches.jpg
The trunk is 23" wide and will overhang the bracket 4 1/4" on each side. And yes, the saddle bags will clear the trunk by 3/4" when opened. http://s2.images.proboards.com/grin.gif
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/23Inches.jpg
The finished rack.
http://i717.photobucket.com/albums/ww179/Stan7442000/Trunk%20Rack/Rack.jpg
Until I get the trunk and remove the sissy bar I cannot determine exactly how far the trunk will extend past the end of the bike but I'm guessing 2-4".
I still have to disassemble the rack and take a belt sander to all of the edges. I also have to buy/make spacers for all of the frame bolts to match the recess in the chrome trim. I used washers for the fitting. Not sure if I will just paint it black or match the lower bike color.
Specifics
Side rails: 1/8" Steel
Top Plate: 1/8" Aluminum
Support angle: 1"x1"x 1/8"
Weight: 7.4 lbs. (calculated)
Time: About 6 hours including putting the bike back together.
Rigidity: I literally sat on the rack with no discernible movement other than the shocks compressing. This was never really a worry as my chief concern was horizontal movement of which there was none as I applied what I guessed to be about 50 lbs. of side force to the end of the rack.
So that's it. I have a rack that lets me keep the grab rails and provides a lower mounting point for the trunk.