Built my own tail rack

suprphreak · Apr 21, 2014

Hi all, just thought I would share my build.

I very much enjoy building things, so when I saw a need on my bike, I decided to take the DIY route.

My rack is built from of 3/8" steel, and is very strong. It has support brackets mounted to underneath the bike, off the same posts as the Givi tail rack kit. The tail box will also serve as a back rest for my passenger, so I wanted to make sure it will support whatever is on there, and then some.

For those who are curious: the tail rack screws are M6, and the ones used to mount the lower pannier mounts are M8.

All in all, it took me about 3 hours to make, plus some planning. It cost me about $30 in all parts and materials. I know it isn't as pretty as some retail models, but it is mostly hidden once the luggage is on there. Also, costs a heap less.

zippy49 · Apr 21, 2014

suprphreak said:
Hi all, just thought I would share my build.

I very much enjoy building things, so when I saw a need on my bike, I decided to take the DIY route.

My rack is built from of 3/8" steel, and is very strong. It has support brackets mounted to underneath the bike, off the same posts as the Givi tail rack kit. The tail box will also serve as a back rest for my passenger, so I wanted to make sure it will support whatever is on there, and then some.

For those who are curious: the tail rack screws are M6, and the ones used to mount the lower pannier mounts are M8.

All in all, it took me about 3 hours to make, plus some planning. It cost me about $30 in all parts and materials. I know it isn't as pretty as some retail models, but it is mostly hidden once the luggage is on there. Also, costs a heap less.

A nice job; I like to make my own bits as well. It's a lot more satisfying than just buying something and bolting it on. Now, please brace yourself for some hopefully constructive comments.

Are you sure that's 3/8" thick? Looks more like 3/16" in the pics. Please watch that the struts don't get bent - this will weaken them severely as they are loaded in compression - like a column. Some nice 1/2" x 16 ga. tubing would be ideal and very light. Don't just squash the ends, weld on tabs for the mountings. You would be amazed at what a really rough road can do; I used to do vehicle durability testing on special tracks. My motto was "You make 'em, I break 'em." And I did.

Please forgive the (semi) retired engineer... just trying to help.

suprphreak · Apr 21, 2014

zippy49 said:
Please forgive the (semi) retired engineer... just trying to help.

Greatly appreciated! I'm reasonably sure it is 3/8, but I could be wrong. Either way, its a thickass plate and I'm sure it will hold.

I see what you are saying about the support bracket. I was thinking I might welt an additional piece perpendicular to the existing support to create an "L" bracket, to prevent flex. Thoughts on that?

I like the idea of the flat metal as it obstructs the tail light less.

GTHawk · Apr 22, 2014

I personally would have used L bracket pieces for the support arms. Cut the right angles into them so it welds directly to the main plate. I also would personally bolt things together instead of welding. Ie a bolt comes off I can replace it some what easily and even patch with wire or something to get me to a hardware store. A weld on the road to me if it breaks I have to find a weld shop. Not always easy to find depending on where you are. What you could think about doing is just even drill holes so if worst case of weld breaking happens you can at least use some wire to hold tell you get to a weld shop.

But overall I like the setup.

zippy49 · Apr 22, 2014

Here is a rack I made 20 years ago for my Velo. It's 1/2" x 16 ga. steel tube I scrounged from a header shop. It was leftover EGR tubing. I bent it with a copper tubing bender (well greased), then fitted and polished all the pieces. Took it to a buddy who TIG'ed it together. $20 worth of chrome plating and viola. You would not have to bend or plate this. And it is very light.

The arrows and letters reference a parts list I made. I shortened the lower rails too much, there should be more overlap to the top rail. I can't pick the bike up with it, but it has held up otherwise. I've carried our entire camp kit - tent, bags, pads, cook set - on it many times on the 1000 mile Velo rides.

suprphreak · Apr 22, 2014

That is pretty awesome looking! Very classy!

zippy49 · Apr 23, 2014

The tubing would be ideal in the Hyper application. It has much better column and yield strength than a plain bar of anywhere near the weight. Two pieces with tabs on top and the flat bottom strap would do it. I'd expect to find it at a good metal supply warehouse. You wouldn't need much.

But I'm not interested in carrying that much weight up high and rearward, so I'm not making any!

suprphreak · Apr 23, 2014

Like I said, it is more for a back rest for my wife. Even then, she doesn't much need it, just a place to give reassurance she won't fall off under hard accel. Not much weight will ever go in there (small Givi box, only day supplies). I'll try to find some tube, I expect the same metal shop which had this metal will have it.

Built my own tail rack

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