Daddyjoe's KLR 650

I bought a set of "home made" racks from another lister, but when I got them I decided they wasn't what I wanted. Too much stuff had to be taken off the bike for them to work. But it did inspire me to get off my rear and make my own.

 I went to a local shop and bought some 3/8 solid round bar, ( they didn't have the solid square), and some 1" by 1/8 " flat stock. It was a lot cheeper than I thought it would be. Less than $20 for all I got.

Then I started bending and welding. I had an ideal of what I wanted, I just had to transfer it from my head to the metal I had.

After I got the frame welded together, I needed a way to hold the boxes on the frame. Using what was laying around I came up with this. After the aluminum I tried broke when I tried bending it I had to use this tin. I will find a better way for this someday.

Black paint was sprayed on to protect the metal and hide some of my mistakes. Did I mention I was NOT a welder.

After all was said and done this is what I have so far. I still have to make a few mods to it, but we will be able to use them this weekend on or 3 day trip on the KLRs.

 The top one is mounted to the rear rack. The side racks can be removed with 6 bolts. I had to use longer bolts for the rear foot peg mounts, and I used 4 bolts to connect the two side in the rear of the bike. One bolts to the muffler,rear peg mount, and the other rack. The other side mounts to the rear peg mount, between the rear rack and rear fender, and to the other rack in the rear.

 I will have to make/buy a bracket to secure the boxes to the racks, but for now it will be the brackets to hold the boxes on, and a bungie, or strap to keep them from bouncing off.

The boxes are the army mail boxes I bought at the flea market a few weeks ago. They are strong, light, and water proof.

I built another set of racks for the wife's hard bags, (they are army shipping containers also).  The racks for Marcia's hard bags are almost the same as mine, the exceptions, or modifications are:

 1) It is one peice of round stock bent to make each side and connects each side as one peice, it has the same 1" flat stock welded to the racks, and bolts on the same.(right side mounts to muffle bracket and rear foot peg. The left side mounts between the rear rack and fender, and to the rear foot peg.)

 2) The mounting is diffrent for the boxes, two peices of 1" flat stock is attached to the boxes, with 90* bends, and bolts with a hole drilled in them welded to the tabs. Four tabs was welded to the racks with holes drilled in them. The bolts welded to the tabs on the boxes fit into the holes drilled in the tabs welded to the racks. I then use a retaining pin through the holes in the bolts to secure the boxes to the racks.

 It makes them secure for riding and quick to remove anytime. You could also rig them to put a lock on them for security, but mine just have the pins.