found this old thread I posted to ages ago thought I'd give an update.
well, I build tool box, full rack and have welded up numerous other items, to date I have not had a single joint failure!!!
the rack had done about 10,000km on rough roads and few thousand on sealed roads, 7,000k round aus trip fully loaded.
the rack is 1" tube with a few mitred joints.
I still can't believe how well it has held up.
If anyone is interested i'll take some pics of the rack but I had to butcher it to fit the gsxr muffler.
Oh yeah and I have crashed in the sand fully loaded at about 70kmh and dropped it at least twice at other times with