Soft luggage and Rotopax add-on plate for TT rack and KTM 690 Luggage rack

EDIT 2/27/2016 - New Add-on plates available - http://www.perunmoto.com/products/add-on-plates-for-pannier-racks?variant=15962489862


I ride off road a lot, so I am great fan of soft luggage. My favorites are Kriega and Wolfman, but in the past I used all kind of soft panniers and roll bags. When I ride, I try to go as far as I can, so I am often short on gas, but I am not huge fan of additional gas tanks. That&#8217;s why I fancy Rotopax stuff. <?xml:namespace prefix = "o" ns = "urn:schemas-microsoft-comfficeffice" /><o></o>
Since I ride KTM 690 Enduro, I use Touratech pannier rack, and I am very satisfied with it, strong and well made. <o></o>
But I wasn&#8217;t happy with how soft luggage was intended to mount on TT pannier racks (or any racks). So I designed my own system for strapping soft luggage and/or Rotopax fuel canister.<o></o>
IMG_3006 by MaletaBG, on Flickr<o></o>
Mounting plates are made of 4 mm aluminum sheet. Slots are debbured by hand. Powder coated to mat black. Clamps are high quality Wurth clamps, zinc coated. All mounting hardware is high quality &#8211; torban bolts, washers, nuts, aluminum washers for Rotopax mount and wrench mount. All hardware weights less then 1.3 kg, for both sides. <o></o>
Plates are made for Touratech pannier racks for KTM 690 Enduro, but due to adaptable clamp mounting positions, it can be mounted to any rack that uses 18 mm tubes with same loop &#8211; outer dimensions of the loop 350 mm x 245 mm:<o></o>
IMG_30051 by MaletaBG, on Flickr<o></o>
General idea is to create universal platform so you can strap just about anything to it. Some examples of how it can be use will follow.<o></o>
Rotopax 1 gallon can, in four different positions:<o></o>
IMG_2951 by MaletaBG, on Flickr<o></o>
IMG_2956 by MaletaBG, on Flickr<o></o>
IMG_2961 by MaletaBG, on Flickr<o></o>
IMG_2979 by MaletaBG, on Flickr<o></o>
In any position, Rotopax is sitting on rubber, like shown in following picture, so it&#8217;s very secure. <o></o>
IMG_2964 by MaletaBG, on Flickr<o></o>
Rotopax and Kriega US-10:<o></o>
IMG_2967 by MaletaBG, on Flickr<o></o>
Lot of space to put one US-5 on top:<o></o>
IMG_2970 by MaletaBG, on Flickr<o></o>
Slots are made so Kriega hooks can easily slide through:<o></o>
IMG_2976 by MaletaBG, on Flickr<o></o>
IMG_2974 by MaletaBG, on Flickr<o></o>
Or<o></o>
IMG_2977 by MaletaBG, on Flickr<o></o>
I use Kriega US-10:<o></o>
IMG_2981 by MaletaBG, on Flickr<o></o>
IMG_2982 by MaletaBG, on Flickr<o></o>
IMG_2984 by MaletaBG, on Flickr<o></o>
And US-20:<o></o>
IMG_2987 by MaletaBG, on Flickr<o></o>
IMG_2988 by MaletaBG, on Flickr<o></o>
There is room for US-10 on top:<o></o>
IMG_2992 by MaletaBG, on Flickr<o></o>
I recently aquired Wolfman Expedition bags, so I adjusted slots for Wolfman too:<o></o>
IMG_3000 by MaletaBG, on Flickr<o></o>
IMG_3001 by MaletaBG, on Flickr<o></o>
IMG_2997 by MaletaBG, on Flickr<o></o>
And result (bag attached only to plate just for photo, I use over-the-seat straps too):<o></o>
IMG_2994 by MaletaBG, on Flickr<o></o>
IMG_2996 by MaletaBG, on Flickr<o></o>
There is a system to attach wrench and/or tyre irons on the inner side of plates:<o></o>
IMG_3004 by MaletaBG, on Flickr<o></o>
IMG_3003 by MaletaBG, on Flickr<o></o>
IMG_3005 by MaletaBG, on Flickr<o></o>
Lot of space to strap bag with inner tyres on the inside of plates too. And many, many other options.<o></o>
And it looks cool:<o></o>
IMG_3008 by MaletaBG, on Flickr<o></o>
J<o></o>
Now the not-so-good part. I hoped to achive lower price, but when I add everything I get to the price of 110 EUR or 150 USD. Thats for two plates, mounting hardware (clamps, torban bolts, washers, nuts), aluminium washers and bolts for Rotopax mount (Rotopax mount NOT included), and &#8222;wrench mounting&#8220; hardware &#8211; aluminium plates, rubber, aluminium washers, bolts, washers and nuts).<o></o>
Shipping is 35 EUR or 48 USD &#8211; I use EMS shipping &#8211; delivery time is around 7 days for USA and 5 days for Europe.<o></o>
For first 5 sets special price &#8211; 73 EUR or 100 USD. - First five sets SOLD - <o></o>
If interested, please visit www.perunmoto.com<o></o>
All comments are welcome!

nicely done....

Order placed for tank bolts and TT rack plate.

David

Luggage rack for KTM 690 Enduro

Disclaimer: please disregard bolts I used on the picture. I ordered nice button head bolts, but I am still waiting for them. More than few inmates are asking for the rack, so I made these pictures, even I don't have proper bolts.

IMG_0437 by MaletaBG, on Flickr

IMG_0392 by MaletaBG, on Flickr

So, the story goes like this: I wanted luggage rack for my KTM 690 enduro:

- that is not too big to ruin design of the bike,
- not too big,
- made for soft luggage, with many strapping options,
- with ability to mount Rotopax on top of it,
- sturdy enough to endure rough rides over stone gardens,
- that can easily integrate with Touratech pannier racks.

There are several nice luggage racks for KTM 690 enduro on the market, but non of them ticked all my boxes, so I decided to make my own luggage rack.

Here are two Advrider posts with very first prototype of my rack: post one and post two. Since then, I made several design changes, and here is final CAD model:

Luggage rack 1-page-001 by MaletaBG, on Flickr

Luggage rack 2-page-001 by MaletaBG, on Flickr

Rack is made out of AlMg3 H22 (5754) aluminium sheet, 5 mm thick. Aluminium is cut using water jet. All edges are debbured by hand, to protect luggage straps. Big bend is 20 degrees, with 10mm radii; smaller bends are made with smaller radius, they don't suffer great stress. All bends are perpendicular to grain direction.

In order to achieve greater strength and to minimise vibration stress, luggage rack consists out of two parts - upper and lower, that are connected with two M6 bolts (not shown on CAD model). This will prevent oscillations that could lead to cracks. Bolts are bolted to the rubber element, more of that later.

IMG_0466 by MaletaBG, on Flickr

IMG_0470 by MaletaBG, on Flickr

Here are rubber elements.

IMG_0312 by MaletaBG, on Flickr

IMG_0313 by MaletaBG, on Flickr

Rubber elements do not transfer weight of the luggage to the tail of the bike, they just minimise oscillations of the rack. Below is shown that rubber elements are nut pushing tail of the bike, but just touching it. Once rack become loaded, they will make little more contact, but they are made of soft luggage.

IMG_0398 by MaletaBG, on Flickr

I had in mind two setups, luggage rack alone and luggage rack with Touratech pannier rack.

Luggage rack alone:

IMG_0451 by MaletaBG, on Flickr

IMG_0455 by MaletaBG, on Flickr

IMG_0442 by MaletaBG, on Flickr

IMG_0457 by MaletaBG, on Flickr

IMG_0459 by MaletaBG, on Flickr

IMG_0445 by MaletaBG, on Flickr

And with Touratech pannier rack:

IMG_0392 by MaletaBG, on Flickr

IMG_0395 by MaletaBG, on Flickr

IMG_0391 by MaletaBG, on Flickr

IMG_0394 by MaletaBG, on Flickr

IMG_0397 by MaletaBG, on Flickr

IMG_0403 by MaletaBG, on Flickr

IMG_0404 by MaletaBG, on Flickr

Two sets of aluminium bushings are provided - one for rack alone and other for using luggage rack with Touratech pannier rack.

IMG_0315 by MaletaBG, on Flickr

1 gallon Rotopax container can be attached to the rack, using standard Rotopax mounts. Bolting Rotopax mount to the rack will contribute to the strength of the assembly, because bolts for Rotopax mount will go through lower and upper part of luggage rack and will bind them together even more.

IMG_0410 by MaletaBG, on Flickr

IMG_0413 by MaletaBG, on Flickr

IMG_0411 by MaletaBG, on Flickr

IMG_0430 by MaletaBG, on Flickr

This rack was designed to carry smaller soft bags (ie. Kriega US-10) and/or Rotopax container (1 gallon). It can carry as much weight as mounting points (bolts to the plastic tank) can endure, but I don't recommend putting more then few kilograms to the back.

Price for the rack is 120 USD/90EUR plus shipping.

If interested, please visit www.perunmoto.com


P.S.

I am working on larger add-on plate, that will bolt onto this rack, so larger duffels and bigger Rotopax containers could be carried. Holes for attaching add-on plate to the rack are already there.

Order placed. Just what I needed!

That was pretty quick. Won't have time to try them out for a week or so as I'm out of town, but they look nice.

Thanks
David

I would need the racks first your racks look pretty cool who makes them do you have a link

Toratech is making pannier racks.

Aaaaaand they're gone!

I'll be keeping an eye out. That's exactly what I'm looking to do with my TT racks and Wolfman bags.

Thanks!
​

Until I make instruction manual...

A. INSTLATION

1. Proper positioning of the clamps, flat part is on the inside:

IMG_0324 by MaletaBG, on Flickr

2. Starting point. Mount all clamps to the rack. Then bolt plate to upper clamps. Don't forget washers. Don't tighten the bolts yet.

IMG_0328 by MaletaBG, on Flickr

3. Pull the plate down.

IMG_0332 by MaletaBG, on Flickr

4. Bolt two lower clamps. Don't tighten it yet.

IMG_0340 by MaletaBG, on Flickr

5. Lower side clamps next.

IMG_0342 by MaletaBG, on Flickr

6. Then remaining two.

IMG_0343 by MaletaBG, on Flickr

7. Once you mounted all clamps, tighten the bolts. Don't over tighten, they are going nowhere, safety nuts are used.

B. ROTOPAX MOUNT

Rotopax can be mounted in various positions, up to your preferences and setup.

1. Use two M8 bolts and washers from the inside.

IMG_0344 by MaletaBG, on Flickr

2. Use two aluminium bushings on the outside.

IMG_0345 by MaletaBG, on Flickr

3. Then bolt Rotopax mount.

IMG_0346 by MaletaBG, on Flickr

4. Rotopax container should "sit" tight on the clamp rubber.

IMG_0350 by MaletaBG, on Flickr

I do not recommend riding with just Rotopax mount (without Rotopax container on it). It is 2 minute job to dismount Rotopax mount.

C. WRENCH/TYRE IRON MOUNT

For photo shooting purposes, I mounted wrench on the outside. It is supposed to be mounted on the inside.

1. Install four torban bolts.

IMG_0353 by MaletaBG, on Flickr

IMG_0351 by MaletaBG, on Flickr

2. Install aluminium bushings.

IMG_0355 by MaletaBG, on Flickr

3. Glue rubber band to the plate.

IMG_0354 by MaletaBG, on Flickr

4. Position the wrench and tighten it using provided small aluminium plates. For safety reasons I provide safety nuts instead of "butterfly nuts" shown on photo. Use rubber band as shown in photo, but cut it to desired length. Rubber bend can be glued to inside of small mounting plates too.

IMG_0357 by MaletaBG, on Flickr

Have fun and travel to nice, remote places.

I finally took some time to finish Luggage rack for KTM 690. I didn't want to make separate thread for it, so I just edited one of my previous posts in this thread - http://www.advrider.com/forums/showpost.php?p=24393812&postcount=4.

I would appreciate any comments!

I just installed the Right side as I'm not carrying anything on the exh side at the moment. Strapped a small Kriega bag to it with tools/spares. I think it works quite nice and is very well done. I've ordered some RotoPax mounts and cans so I can extend my range a bit. I'll put the other side on when I need to use those. Not quite sure on spending the big $$ on some add on tanks yet.

David

INSTRUCTIONS FOR LUGGAGE RACK

A. Luggage rack w/o Touratech pannier racks

1. Remove grab handles. Clean the threaded inserts (the one grab handles were bolted to).

2. Insert longest spacers provided with Perun moto rack (20 mm) and align them well. Make sure no wires are pinched.

IMG_0382 by MaletaBG, on Flickr

3. Rack should be preassembled, but make sure rubber elements are properly bolted.

IMG_0466 by MaletaBG, on Flickr

4. Position the rack and align it well. Use middle size spacers (13 mm) between upper and lower rack plate. Use M8 washers and provided bolts (instead of standard bolt used on the picture, nicer button head bolts are provided). Consider using anti seize lubricant on bolts.

IMG_0422 by MaletaBG, on Flickr

5. Tighten all bolts evenly. Don't over tighten, 15 - 20 Nm is enough.

B. Luggage rack and Touratech pannier racks

1. Loose all bolts used on TT rack, but don't remove the rack.

IMG_0375 by MaletaBG, on Flickr

IMG_0374 by MaletaBG, on Flickr

IMG_0379 by MaletaBG, on Flickr

2. Remove bolts and spacers of the TT rack. Insert longest spacers provided with Perun moto luggage rack (20 mm).

IMG_0382 by MaletaBG, on Flickr

3. Align TT rack and Perun moto luggage rack, as shown in pictures:

IMG_0384 by MaletaBG, on Flickr

IMG_0383 by MaletaBG, on Flickr

4. Use shortest spacers (9 mm) between TT rack and upper plate of Perun moto rack, as shown in picture:

IMG_0385 by MaletaBG, on Flickr

5. Insert bolts provided with Perun moto rack (instead of standard bolt used on the picture, nicer button head bolts are provided) and M8 washers. Consider using anti seize lubricant. Don't tighten the bolts yet!

IMG_0405 by MaletaBG, on Flickr

6. Tighten all bolts evenly (don't forget bolts for TT rack). Don't over tighten, 15 - 20 Nm is enough.

Received my plates and installed them today.

First of all I have to say that dealing with Nikola is really a pleasure. Very nice person.

Here are a few pictures of the installation. Everything went very smooth and quality of the parts is perfect.

This is what you get. Plates and all bolts you need for the installation.












This are the parts for the roto-pax and tool mounting. I have not installed it yet.


When I mounted the Wolfman bags I relalized the mounting is a bit close to the bolts. No Problem ... I just changed the positioning of the clamp.


This is very easy, as there is already a second hole in the plate. And everything looks perfect. Mounting the bags is now really quick and easy.


And this is the complete setup with the Wolfman bags.


Thank you Nikola.

Hi Tobias, thanks for posting. Black rack is looking great!

I received the rack a couple of days ago and finaly today I had to time to install it!

The rack is top notch quality, is built like a tank from excellent materials and I'm really glad with the purchase.

Nikola thanks for all the help during the transaction, you were really helpful and thanks for the great products !

Here are some quick photos I snapped after I installed the rack.

<iframe class="imgur-album" width="80%" height="450" frameborder="0" src="http://imgur.com/a/Bq5c1/embed"></iframe>

I now have to find the time to install the tank bolts :)

Glad you like it, hope we will see some adventure photos with it soon... :)

Leaving for vacation in few days, everything purchased before July 24th will be shipped one day after the purchase. For purchases after that date, items will be shipped on August 7th.

Since I am leaving for a vacation, and I have two sets of
Soft luggage and Rotopax add-on plate for TT rack left from this batch, I am offering them at the special price - 120 USD instead of 150 USD. Deal is on for next two days. If interested, check http://www.perunmoto.com/collection...luggage-and-rotopax-add-on-plate-for-tt-racks.

---Deal ended---

hi, great set up but would you make smaller plate? i don't know the brand of my luggage rack but the inner dimension ( from tube to tube) are 275mm by 165mm.
thanks
nick

Hello, Nick!

Well, I believe it is possible. Rack is square, right? What is diameter of tube? A picture would be nice, to see where to make holes for clamps. I will check it in CAD, as soon as I get back home, in a week.