custom pannier rack for a KLR

Discussion in 'Thumpers' started by ganshert, May 7, 2006.

  1. ganshert

    ganshert not sleeping

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    I didn't like any of the racks available for the KLR so I made my own. This is what I needed to do the job

    1 each 10" touratech pannier
    1 each 8" touratech pannier
    2 each 18mm touratech steel mounting "hoops"
    2 each 18mm touratech mounting puck kits
    5 or so feet of 3/4" steel tubing
    some 3/16 flat stock
    fasteners that I had laying around
    2 each Kawasaki stickers :thumb

    mounted the pucks to the panniers
    calculated where I wanted the panniers width wise
    zip tied the panniers lid handle things to 2 four foot bar clamps spaced correctly
    set them on top of the bike and got them where I wanted them
    fabricated and welded the supports where I wanted them
    put on the cool stickers

    results
    [​IMG]
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    next step is to make a top rack and turnsignal mounts and go see if I can break these :D
    #1
  2. PackMule

    PackMule love what you do Super Moderator

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    Dang, man. Wish I had skillz like you. :nod


    What do you do for work?
    #2
  3. ganshert

    ganshert not sleeping

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    I'm a project manager, I stare at a computer all day
    #3
  4. PackMule

    PackMule love what you do Super Moderator

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    :lol3 You sure make up for it on the weekend! :beer :bow

    Now get back to work on the fairing! :1drink
    #4
  5. VHRAM

    VHRAM Been here awhile

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    :clap looks great
    #5
  6. ganshert

    ganshert not sleeping

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    So nobody has any constructive criticism for me?
    #6
  7. Mr. Annoying

    Mr. Annoying B.F.aC.G

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    Ya more pictures..... now get to work ,,, damn it:lol3
    #7
  8. anatinae

    anatinae As Bad As Can

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    Yeah, why didn't you make your own boxes?:rofl
    #8
  9. duckrider

    duckrider Been here awhile

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    Nice rig. What are you using for headlites?
    #9
  10. ganshert

    ganshert not sleeping

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    #10
  11. sleepywombat

    sleepywombat the DR650 pig

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    they're on the wrong bike :lol3
    #11
  12. GB

    GB . Administrator

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    How about providing them to Touratech? They don't sell a thing for the KLR. The "mounts" that they recommend are the Happy Trail SU mounts for mounting their Zega cases..
    #12
  13. KLR650dotnet

    KLR650dotnet Banned

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    Very nice work! Looks GREAT.:clap
    #13
  14. Hannda

    Hannda Short, fat, bearded, slow

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    OK, it looks like once again I'll be the one willing to look like an idiot and ask.
    Why the two different sizes for the panniers? One 10" and one 8" if I read, and understood, your post correctly. The rack appears to be equidistant from the centerline of the bike, so it doesn't appear that you need one thinner than the other to accommodate the exhaust pipe . . . . so what's the real reason?:ear
    #14
  15. Speaker

    Speaker Been here awhile

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    rack looks great, wish i had the skills/tools to do that. If i might ask what sort of headlights those are and where you bought them? :evil
    #15
  16. ganshert

    ganshert not sleeping

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    the right side rack is 2 inches further from the center than the left rack to accomodate the exhaust pipe

    the outside of both boxes is 18.5 inches from the center of the bike
    #16
  17. Hannda

    Hannda Short, fat, bearded, slow

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    Will that cause balance issues? Or do you just have to be careful when loading them - weight-wise?
    #17
  18. RT jim

    RT jim Long timer

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    Looks good I need a sheet metal brake to build boxes. I''ve got .090 aluminum I use everyday. What's the material thickness on the boxes MR.HANDYMAN. Make your own bender or buy one?
    #18
  19. RT jim

    RT jim Long timer

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    I mean on the rack holding boxes.
    #19
  20. Scribe

    Scribe £Bob£

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    I want to do something similar for my DRZ. How did you bend the tubing?
    #20