Building a V2K Rack

[Lobocop]

Last summer I had decided to build one more rack and finally got started on it.

The way I have been building them is easy, really doesn't require a lot of specialty tools (although it helps to have some) and they can be made of aluminum, stainless or mild steel.

I started out by using the reflector brackets off the sissy bar to get the correct hole spacing and contour to match the sissy bar plates on the V2K. Using those brackets I created a cardboard mock-up that actually bolted to the sissy bar where I could then tape more cardboard pieces in order to get the correct angle of the support beams ... making them level and flow with the bike. After getting the cardboard support beams in the correct position the main rack plate was cut to fit.

After the mock up was completed I took it apart and used it as a template on 1/8" steel plate (mild steel).



I happen to use a plasma cutter, but a good saber saw with a fine tooth blade will also cut mild steel. If you are good with a cutting torch it can be used also, but the heat will create extra work getting the warpage out of the steel.



I opted to add a design to the main plate and cut that out with the plasma cutter also. For the design cut outs I drilled some pilot holes to aid in the cutting process.



Although the plasma cutter makes a nice cut, some cleanup is required with a small grinder and files (especially for designs added). Once the edges are cleaned up on the support beams I drill the mounting hole. Then the real work begins with the files making the cut outs straight and flowing in prep for painting along with taking the sharp edges off.





Tomorrow the welding jig and welding it together.

Oh, Paul Jr., you aren't the only one who can make sparks!

[likearock4x4]

Looking good so far, Ken. I can't wait to see the finished product.

[RichLockyer]

Wish I had a plasma cutter

Looking sharp. I went a slightly different route, using commercial angle stock for the bulk of the rack, but the Cobra backrest for the 1600 has much narrower spacing than the V2K/Nomad/900 backrest. It eliminated a lot of welding, but also a lot of options too.

http://personal.linkline.com/rlockye...k/DSC00616.JPG
http://personal.linkline.com/rlockye...k/DSC00617.JPG
http://personal.linkline.com/rlockye...k/DSC00618.JPG

For the trunk lid rack, I went with 1/2" tubing. The sides are 3/4" bar stock, cut and welded to make the kickup angle at the back.
Legs were attached by clamping them in a vise and drilling with a 1/2" bit to fishmouth the ends:

http://personal.linkline.com/rlockye...k/DSC00614.JPG
http://personal.linkline.com/rlockye...k/DSC00615.JPG

Completed, powdercoated, and mounted:
http://personal.linkline.com/rlockye...k/DSC00681.JPG
http://personal.linkline.com/rlockye...k/DSC00682.JPG
http://personal.linkline.com/rlockye...k/DSC00683.JPG
http://personal.linkline.com/rlockye...k/DSC00684.JPG

I drilled and tapped the side plates of the trunk lid rack and ran stainless screws in, then ground the screws flush on the inside. After powdercoating, I reinstalled the screws with red Loctite.

[CheriAnn]

Looking mighty fine there Ken!!!!


Oh, and the rack is looking good too!

[Lobocop]

After cutting the first three pieces cut out I built a welding jig which was simply two pieces of steel drilled to match the mounting holes in the support beams and welded to some angle iron. It is critical to make sure the holes from one side to the other are aligned or the rack could be welded together out of square.

The welding jig with the support beams bolted in place, the main plate sitting in position and clamped solid.



Once in position I tack welded the plate (from the under side) to the support beams up to the first corner.



Once both sides were tack welded I bent the support beams in to match the countour of the main plate and welded it all in position.



Using some 1 1/4" X 1/8" steel strap that I found at Home Depot I cut some fill material to finish going down the sides of the main plate and then I cut the end piece welding it all together.





Once all the fill and support material are welded into place the final touches with the grinder, files and sanders will begin. Maybe tomorrow for some of that.

[Lobocop]

Originally Posted by CheriAnn

Looking mighty fine there Ken!!!!


Oh, and the rack is looking good too!

Awhhhh shucks, Cheri

[2WheelFun]

Ken, that is looking nice and the "How To" pics and step by step is very informative. You do nice work!!!

I'm curious about the glasses that you are wearing while using the cutting torch. Are those special glasses to use while cutting?

Just a few weeks ago you were hauling your tools into your shop to get it setup and now your building things in it. How cool is that!?

Thanks for sharing with us. One day I'd like to try welding. It's one trade I've never enjoyed yet.

[likearock4x4]

Nice, Ken. You painting that to match the bike??

[CycleDude]

Wow, Ken. You do great work.

[trikebubble]

Great stuff Ken.
Just watch those sleeves in that drill press buddy. (yeh, I gotta help out you young guys with my mature advice every now and then you know...... )

[ImpactG]

Wow! Look at you all up in your shop!

Where do they mount, Ken? To the fender struts?

And if so... what can I do to convince you to build one for me... $? That would be great to put on/take off the rear fender so I could strap a pack to the bike for trips...

[Lobocop]

Originally Posted by trikebubble

Great stuff Ken.
Just watch those sleeves in that drill press buddy. (yeh, I gotta help out you young guys with my mature advice every now and then you know...... )

Thanks for tip, buddy. Had plenty of clearance ... this time

[Lobocop]

Originally Posted by 2WheelFun

I'm curious about the glasses that you are wearing while using the cutting torch. Are those special glasses to use while cutting?

Thanks for sharing with us. One day I'd like to try welding. It's one trade I've never enjoyed yet.

Thanks, Cary.

It is great to have everything up and running again with room to spare

With plasma cutters all you need are dark sunglasses and those that they sell for using with the PC are expense. I have a tendency to take the glasses off, toss them aside and finding them later as I toss a piece of steel onto them. Its cheaper to get several pairs at the dollar store that work just as well.

[Lobocop]

Originally Posted by CycleDude

Wow, Ken. You do great work.

Thanks, Kevin.

[trikebubble]

Originally Posted by ImpactG

Wow! Look at you all up in your shop!

Where do they mount, Ken? To the fender struts?

And if so... what can I do to convince you to build one for me... $? That would be great to put on/take off the rear fender so I could strap a pack to the bike for trips...

Todd, I was thinking of taking my rear fender rack off and coming up with some sort of bracket that fit over the rear fender and secured onto either the Ghost Bracket bolts, or Ghost Brackets themselves.

That way, when I'm not travelling I can have a clean rear fender.

Oh yeh, I have never strapped my T-Bag to a passenger (or drivers) backrest ever anyways. I've just secured it via tie downs at the front and back to my Ghost Brackets. It stays very secure, doesn't move an inch.

[ImpactG]

Originally Posted by trikebubble

Todd, I was thinking of taking my rear fender rack off and coming up with some sort of bracket that fit over the rear fender and secured onto either the Ghost Bracket bolts, or Ghost Brackets themselves.

That way, when I'm not travelling I can have a clean rear fender.

Oh yeh, I have never strapped my T-Bag to a passenger (or drivers) backrest ever anyways. I've just secured it via tie downs at the front and back to my Ghost Brackets. It stays very secure, doesn't move an inch.

Well, that's what I'm thinking Carlo... a rack with slotted mounts where you can loosen the Ghost/Easy bracket bolts and slip it in or out, then tighten. With luggage, all the force will be straight down onto the mounts and without, the weight is negligable so their wouldn't be an issue of it coming free.

Easy on, easy off and one that looks custom to my ride... just sayin' Ken.

[trikebubble]

Originally Posted by ImpactG

Well, that's what I'm thinking Carlo... a rack with slotted mounts where you can loosen the Ghost/Easy bracket bolts and slip it in or out, then tighten. With luggage, all the force will be straight down onto the mounts and without, the weight is negligable so their wouldn't be an issue of it coming free.

Easy on, easy off and one that looks custom to my ride... just sayin' Ken.

Exactly!!!!!!!

[Surftechuser]

Wow, great work! I admire you guys that don't have to buy but build it yourself.

[Lobocop]

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