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Old 03-09-2014, 04:38 PM   #1
duckman44 OP
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Location: Western NY
Oddometer: 134
Rear Rack for a KTM 625 SMC

I have been looking for a rear rack for my 2005 KTM 625 SMC for a while now. Not having any luck, I decided to build one.
I found a rack for a KTM 950 on Flea Bay for $49.00. I thought that was a good deal even if I only used the top plate. They sell for about $79.00.
Here is what I got from that deal.



I started by stripping the rear plastic off so that I could see where to put some mounts.
The exhaust mounts looked strong and there were two on each side.
I started making side mounts.



I mad the holes in the side bars so that the original mounting bushings would fit inside. A few well placed bends and they fit nicely.
I bolted them on and then tried the plastic to see if it needed trimming.







Once both sides were fitted, I cut them down to size and started making the top plate mounts. I clamped them together so that I could get them tacked in. The side arms are 3/16" steel and the upper mounts are 1/8". Plenty strong. Not set up for aluminum in my temporary winter work area.





I cut the plate mounting arms apart and only used the two upper portions of the arms. I had to fill in with weld where the arms were cut off.




I started to trial fit the plate and see how high I wanted it and how far back. This is pretty much how it ended up.
Notice that I used hex head bolts for now. This will change in the next few pictures.



A little trimming was required for clearance. Not much though!







Once I was happy with how it sat, I cleaned up my welds and got the parts ready for a quick satin black paint job. My powder coat gun just took a shit so I will have to wait till later in the spring to powder coat the parts.



Now to those screws. The bolts that came with the rack were very long and made obviously for a different bike.
I had some stainless screws around and fixed them up on my lathe to fit the tapered holes on the top plate.
The rear ones were drilled and tapped so shorter and fatter bolts were in order.





Now all the fabrication is done and it is bolted on.
It looks great to me and is very strong. I can put all of my weight on it and it only sags a little. The only chamnge I may make would be to change the angle so that it sits a little more level. Easy to do.

So, what do you think of my Sunday Project? It was better than sitting around watching TV like I have been doing too much of this super cold winter.




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"Life is Tough, Life is Tougher if you're Stupid" - John Wayne (and my Dad)
2013 Ducati Multistrada GT - 2008 Ducati 1098
2005 KTM 625 SMC - 1976 Moto Guzzi Convert (Auto) - 1964 Ducati 90 Mountaineer
1977 Yamaha XS 400 Cafe Racer - 1976 Honda CB 750 Cafe Racer
1968 Triumph 650 Old School Chopper - 1982 Yamaha 750 Virago
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Old 03-11-2014, 01:05 AM   #2
Te Hopo
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Very nicely done, looks very sturdy and almost factory
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Old 03-11-2014, 02:41 AM   #3
R&R4adv
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great fab work but you might want to make another brace under the rear guard so you can support the back of the plate because if you don't it will vibrate and crack the front mounts when you have gear strapped to the plate, I know this might mean you have to drill some hole through the guard this is the way they are mounted to the 950/990's
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Old 03-11-2014, 02:45 AM   #4
duckman44 OP
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Quote:
Originally Posted by R&R4adv View Post
great fab work but you might want to make another brace under the rear guard so you can support the back of the plate because if you don't it will vibrate and crack the front mounts when you have gear strapped to the plate, I know this might mean you have to drill some hole through the guard this is the way they are mounted to the 950/990's
I think you are right. I checked with static weight but riding will be a whole different story.
I guess a few holes through the fender won't hurt too bad. I most likely will never remove the rack anyway.
Thanks for your comments.
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"Life is Tough, Life is Tougher if you're Stupid" - John Wayne (and my Dad)
2013 Ducati Multistrada GT - 2008 Ducati 1098
2005 KTM 625 SMC - 1976 Moto Guzzi Convert (Auto) - 1964 Ducati 90 Mountaineer
1977 Yamaha XS 400 Cafe Racer - 1976 Honda CB 750 Cafe Racer
1968 Triumph 650 Old School Chopper - 1982 Yamaha 750 Virago
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Old 03-12-2014, 04:45 PM   #5
duckman44 OP
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Quote:
Originally Posted by R&R4adv View Post
great fab work but you might want to make another brace under the rear guard so you can support the back of the plate because if you don't it will vibrate and crack the front mounts when you have gear strapped to the plate, I know this might mean you have to drill some hole through the guard this is the way they are mounted to the 950/990's
I took your advice and made a rear mount. There was not room to extend the two rear mounting points down because the fender mounting holes lined up with the rack mounts.
I made a cross piece and put a center stud that goes through a new hole in my fender and sits on the rear frame. I'll snap a picture tomorrow after it is all buttoned back up. Thanks!
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"Life is Tough, Life is Tougher if you're Stupid" - John Wayne (and my Dad)
2013 Ducati Multistrada GT - 2008 Ducati 1098
2005 KTM 625 SMC - 1976 Moto Guzzi Convert (Auto) - 1964 Ducati 90 Mountaineer
1977 Yamaha XS 400 Cafe Racer - 1976 Honda CB 750 Cafe Racer
1968 Triumph 650 Old School Chopper - 1982 Yamaha 750 Virago
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Old 03-30-2014, 06:57 AM   #6
4x4runer
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nice job. the post says 05 but the bike has dual exhaust? I thought the 06 came with the duals. I would like to fab up something for my 06 so I could hang panniers off the side. would like to see some updated pics
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Old 03-30-2014, 12:11 PM   #7
duckman44 OP
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Quote:
Originally Posted by 4x4runer View Post
nice job. the post says 05 but the bike has dual exhaust? I thought the 06 came with the duals. I would like to fab up something for my 06 so I could hang panniers off the side. would like to see some updated pics
It is an 05
04 was the last year for single exhaust.
I will take a few shots to show the new rear suport.
I am riding this bike from NY to Deals Gap in two weeks.
I purchsed some cheap soft bags from Motorcycle Superstore a few weeks back.
I think I can get away with hanging them over the seat without any mounts.
I will put some clear vinyl protector over the plastic to prevent rubbing for the trip.
I plan to bolt on a Rotopax fuel cell to the rear rack and strap junk on top of it.
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"Life is Tough, Life is Tougher if you're Stupid" - John Wayne (and my Dad)
2013 Ducati Multistrada GT - 2008 Ducati 1098
2005 KTM 625 SMC - 1976 Moto Guzzi Convert (Auto) - 1964 Ducati 90 Mountaineer
1977 Yamaha XS 400 Cafe Racer - 1976 Honda CB 750 Cafe Racer
1968 Triumph 650 Old School Chopper - 1982 Yamaha 750 Virago
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Old 03-30-2014, 02:08 PM   #8
duckman44 OP
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Rear support complete

Here are a few shots of the rear center support.
Like the rest of the rack, it is not powdercoated yet.
When I return from my trip, I will take it apart and powdercoat it.
For now, it is functionable. Once it goes throught the fender, it sits right on a metal support bar. If I wanted to take it off, a simple rubber plug would cover the hole and not look too bad.




I started to fit the soft bags today. I like how I can run the rear strap undr the mount. It makes me feel like it is more secure.
The bags come with quite a few straps. I think they will stay put but I worry about the heat from the mufflers. They don't seem to get that hot but........


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"Life is Tough, Life is Tougher if you're Stupid" - John Wayne (and my Dad)
2013 Ducati Multistrada GT - 2008 Ducati 1098
2005 KTM 625 SMC - 1976 Moto Guzzi Convert (Auto) - 1964 Ducati 90 Mountaineer
1977 Yamaha XS 400 Cafe Racer - 1976 Honda CB 750 Cafe Racer
1968 Triumph 650 Old School Chopper - 1982 Yamaha 750 Virago
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Old 04-11-2014, 09:37 AM   #9
CollinsB
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Looks good!
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Old 06-08-2014, 06:26 PM   #10
4x4runer
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what about fabing up some alum. heat shields, cant be that hard after all that. looks good
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Old 06-10-2014, 10:57 AM   #11
duckman44 OP
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Quote:
Originally Posted by 4x4runer View Post
what about fabing up some alum. heat shields, cant be that hard after all that. looks good
I made a couple of slip on heat shields out of a header wrap cloth. They go on and off in a minute when I choose to use the bags. Works well and the bags stay fairly cool.
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"Life is Tough, Life is Tougher if you're Stupid" - John Wayne (and my Dad)
2013 Ducati Multistrada GT - 2008 Ducati 1098
2005 KTM 625 SMC - 1976 Moto Guzzi Convert (Auto) - 1964 Ducati 90 Mountaineer
1977 Yamaha XS 400 Cafe Racer - 1976 Honda CB 750 Cafe Racer
1968 Triumph 650 Old School Chopper - 1982 Yamaha 750 Virago
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