Well done. I am about to equip my 1984 xt600 with panniers. Your design and installation gave me some great pointers. Thank you. Harbor Freight has a great tough plastic Pelican knock off cases for $60. Perfect size for my need.
Dude, that is an excellent job! You built and awesome rack for the Panniers. You should SELL those! Ever think of that??? A good pannier system is extremely expensive -- and if you can build something that good, and price is lower than the name brands, you might have an awesome side business!
Well done! I've been kicking around the same idea myself, hanging side racks off a top rack. This would be on a DR650. Your video is a great help toward getting my own setup figured out. Thanks! Good idea bolting the side racks to the top rack.
That's a pretty well thought out design and the best part is that for a home-made rack system, they don't look ridiculous. I've seen plenty of home-made rack systems on UA-cam that just make me cringe, but this is not one of them. Nice job!
I finished my panniers racks this week. I don't think thy turned out as nice a yours did but it was a fun project. First time I've ever welded and had a blast. I don't have a video yet but thanks for sharing your video, it definitely helped us along the way. Now it's one to save up for some aluminum sheeting to make some panniers.
thanks for the video Zeuki1. I have some tube steel I wanted to use up but tube = bending whereas square = cutting. I think your idea is better and easier to mount.
I'm far from being a welder but I can weld and I have tons of fabrication experience from Chinook helicopters to nuclear power plants to robots and I gotta tell you, I think you did a nice job. I bought my 2012 KLR 650 4 days ago and I've been looking at racks to buy but not anymore.
Thanks man, yeah these are built to be drop proof... cause I am no MX pro but I love getting out there ! If you can I would definitely go home-made over some of the wire and sheet metal options out there !
Can you post the measurements and angles in your description? I love them but I have to explain to my welder how to build them. You did an awesome job- you could sell these I m sure. I'd buy a pair.
For hard cases I simply drilled holes through frame and case and bolted using elevator bolts and fender washers... not high tech but it worked. For soft cases its just a matter of strapping around the rack and cinching down your dry bags, hope this helps and thanks for the comments !!
Thanks Z, i am planing to use ammo boxes, just playing with them, eventually i ll get other if these don't do the job. Not i qm lazy but could you link a pic of these elevator bolts and fender washer, seriously i got not clue how they look like. In fact the motorbike i got is an old yamaha xt350, and honestly i don't think the boxes will look so goon on it, maybe i should keep them for the the bike, i am planning to get a Ducati enduro, not yet but for my bd, in any case do you mind to link those pics pls. Many thanks and i agree with those saying that you should sell these frames/racks.
Just came across your video. Great racks! They may be heavier than some of the racks with aluminum frames, but I like the way you positioned them to protect both the side covers and the rear turn signals. The fact that these can also be used as handles or for tie downs is a real plus. Once again, excellent job designing and fabricating a nice bit of equipment. They look like pro kit to me. Now, what kind of paniers?
Bravo on that design. Robust and practical. Are you by chance east of the Cascades? I am literally designing a set for my 2011 KLR, yet I think I like your set up a little better. Any idea what it weighs? I am in Spo. Again, well done sir.
Thanks for sharing, I'm going to copy you on my Aprilia Pegaso too.... I'm wondering, did you find a place to order hinges when making your own boxes? How about locks, gaskets, and mounts? We finished up Mr.Rohonecks racks, and holy cow, these things are solid!!
Hi, thanks for the video, I found it very inspiring, I to am looking to create a rack in then next few weeks, do you happen to have measurements or a diagram. I’ve never fabricated something of this scale, I don’t wish to waste steel as it is expensive. Any additional advice would be greatly appreciated
I wish I had made a build video for these, I get alot of requests. Unfortunately like most things I build, its all off the top of my head with no plans written down. I sold the bike a number of years ago. The best advice I can give is take your time and dont get too hung up on measurements as the klr isnt built perfectly square. I put two sets of these racks on two different bikes and neither of them would have been able to bolt onto each other. I would start with the top rack, get it done and bolted in then build the side "squares". Hang them into place with the down tubes being mindful of your positioning on both sides ... make sure it is set equal so you wont create a weight imbalance. once tacked in place attach the forward bars that connect to the foot area and watch that you dont crowd the passenger foot area ( if you will ever take passengers). Then measure and build the rear tie bar. Hope this helps, and good luck setting up your bike !
Curious what your welding setup consists of. I was thinking of picking up a rig from Harbor Freight at their next parking lot sale and want to plan what's needed. Can you list all the tools you used including any torches, pipe benders, welding rig, etc? Thanks man. Very great setup BTW
Honestly not much, they worked well. I Sold this bike, but have a friend who I built a set for that still work well. When I made these there were no real solid options available on the market that were reasonably priced. Recently I purchased another KLR that had the Tusk brand pannier racks and the quick disconnect mounts, they seemed decent for the money and felt pretty sturdy, hard to beat for the price if you do not have access to a welder and shop.
Dude I love your rack hahaha -- seriously super sturdy--- any chance you could upload measurements for the top main rack? where all the holes are and width etc? the one you replaced the plastic top with
Honestly I don't remember exactly. I was getting the metal at cost, about a dollar a foot, 20-30 bucks total. its cheapest to buy it from a wholesaler and buy it in 20 foot sticks. box stores mark it up 100-200%. The rest of the stuff I had on hand so I have no Idea what the out of pocket woud be to buy again, nuts and bolts wise, markup at places like lowes, ace etc is crazy and is as much as the steel.
Just ordered some square tubing to make the same rack system you've made. Hopefully mine turns out half as decent as yours look and I'll be happy. Any updates or issues that you've encountered since you've uploaded this video? What plans do you have for panniers? I think I'm going to order aluminum online and weld my own boxes too. I looked online the other night and figured I could make large boxes for almost $100 a piece instead of $300 a piece from some lame business. Ride safe!
Top Job! Gives me some inspiration to build my own pannier racks.
Im glad, once you get started its all down hill... hope you do build them !
These are the best looking and functional racks I've seen. Well engineered, great job. Thanks for sharing.
Well done. I am about to equip my 1984 xt600 with panniers. Your design and installation gave me some great pointers. Thank you. Harbor Freight has a great tough plastic Pelican knock off cases for $60. Perfect size for my need.
Great craftsmanship. They seem very strong.
Dude, that is an excellent job! You built and awesome rack for the Panniers. You should SELL those! Ever think of that??? A good pannier system is extremely expensive -- and if you can build something that good, and price is lower than the name brands, you might have an awesome side business!
True
sweetest DIY rack for a klr I have seen to date!
Awesome Brother! Nice build and rewarding too. Thumbs up
Nicely done, Very clean job, some real craftsmanship there, I bet you could market those!
It is pretty nice build and strong, I am just having this model but will build one too. Thanks,for your sharing.
Well done! I've been kicking around the same idea myself, hanging side racks off a top rack. This would be on a DR650. Your video is a great help toward getting my own setup figured out. Thanks! Good idea bolting the side racks to the top rack.
I used your idea for this rack and it turned out great! Very strong and looks great, thank you for the idea, i love it!
Thanks for the cost-saving tips/ideas!
Safe ride!
Happy New Year 2021!
That setup looks very practical, intuitive, and well built. Keep up the good work!
That's a pretty well thought out design and the best part is that for a home-made rack system, they don't look ridiculous. I've seen plenty of home-made rack systems on UA-cam that just make me cringe, but this is not one of them. Nice job!
Thank you.... it looks like a pretty sweet little tank bag, not to big but just big enough... very cool....
Fantastic, copied your design to a tee.
Nice and solid for a 5 month trip around Australia.
Much appreciated.
Awesome looking rack system! As a KLR owner I look forward to more of ur vlogs.
Nice work Man . Like the way you can detach the side racks .Thanks for the putting the vid up .
very nice they look just as good the ones you can get at happy trails , and they look beefer.
I finished my panniers racks this week. I don't think thy turned out as nice a yours did but it was a fun project. First time I've ever welded and had a blast. I don't have a video yet but thanks for sharing your video, it definitely helped us along the way. Now it's one to save up for some aluminum sheeting to make some panniers.
Amazing work. Well worth the effort. thk you for sharing.
Nice one, mate. Thought about doing that myself. Yours is the DIY rack I've seen. Looks great.
Very nice build
I love the design! great work.
Good design idea and very cost savings.
You did a very grate job man ,
Looks solid dude. Well done.
Bad ass bike bro! I am loathing to get a KLR! Just 8 more months of car payments....... Then I can afford it. Keep the awesome vids coming!
thanks for the video Zeuki1. I have some tube steel I wanted to use up but tube = bending whereas square = cutting. I think your idea is better and easier to mount.
I'm far from being a welder but I can weld and I have tons of fabrication experience from Chinook helicopters to nuclear power plants to robots and I gotta tell you, I think you did a nice job. I bought my 2012 KLR 650 4 days ago and I've been looking at racks to buy but not anymore.
Thanks man, yeah these are built to be drop proof... cause I am no MX pro but I love getting out there ! If you can I would definitely go home-made over some of the wire and sheet metal options out there !
Very nice! Hope you don't mind but I'm pretty much going to copy what you've done. Just going to add a trailer hitch for towing my canoe.
Really nice job, it looks pretty strong !
I'll try to do the same on my 650 DR
Awesome job.My KLR Brother.
Really nice, shows some talent.
Nice work!
You did a great job!
Can you post the measurements and angles in your description? I love them but I have to explain to my welder how to build them. You did an awesome job- you could sell these I m sure. I'd buy a pair.
I am actually getting ready to buy a welder that I can use for Gunsmithing and what not. Would also love to get measurements and angles as well.
Have a look on YT for "how to weld aluminium" - there are
some useful DIY options .... Not as technical as you may envisage :-)
very nice very nice!!
congrats, i was thinking about doing something similar con my xr
what a great job you have done, now could you explain pls how to attach the panniers to the racks. thanks
For hard cases I simply drilled holes through frame and case and bolted using elevator bolts and fender washers... not high tech but it worked. For soft cases its just a matter of strapping around the rack and cinching down your dry bags, hope this helps and thanks for the comments !!
Thanks Z, i am planing to use ammo boxes, just playing with them, eventually i ll get other if these don't do the job.
Not i qm lazy but could you link a pic of these elevator bolts and fender washer, seriously i got not clue how they look like.
In fact the motorbike i got is an old yamaha xt350, and honestly i don't think the boxes will look so goon on it, maybe i should keep them for the the bike, i am planning to get a Ducati enduro, not yet but for my bd, in any case do you mind to link those pics pls.
Many thanks and i agree with those saying that you should sell these frames/racks.
Hi again i just checked google and i got a better idea, in any case pics of the final product might help.
Thanks.
Nicely done!!!!
Just came across your video. Great racks! They may be heavier than some of the racks with aluminum frames, but I like the way you positioned them to protect both the side covers and the rear turn signals. The fact that these can also be used as handles or for tie downs is a real plus. Once again, excellent job designing and fabricating a nice bit of equipment. They look like pro kit to me. Now, what kind of paniers?
Awesome job. Do you have any dimensions or drawings please??
Great job man!
Great job. You got skills !
Great build.
Any chance getting plans and dimensions?
Love the bike bro!
a1 job tks fore sharing. i think you should build and sell on the net. paul
nice job.....grat idea
Bravo on that design. Robust and practical. Are you by chance east of the Cascades? I am literally designing a set for my 2011 KLR, yet I think I like your set up a little better. Any idea what it weighs? I am in Spo.
Again, well done sir.
Thanks for sharing, I'm going to copy you on my Aprilia Pegaso too.... I'm wondering, did you find a place to order hinges when making your own boxes? How about locks, gaskets, and mounts? We finished up Mr.Rohonecks racks, and holy cow, these things are solid!!
Hi, thanks for the video, I found it very inspiring, I to am looking to create a rack in then next few weeks, do you happen to have measurements or a diagram. I’ve never fabricated something of this scale, I don’t wish to waste steel as it is expensive. Any additional advice would be greatly appreciated
I wish I had made a build video for these, I get alot of requests. Unfortunately like most things I build, its all off the top of my head with no plans written down. I sold the bike a number of years ago. The best advice I can give is take your time and dont get too hung up on measurements as the klr isnt built perfectly square. I put two sets of these racks on two different bikes and neither of them would have been able to bolt onto each other. I would start with the top rack, get it done and bolted in then build the side "squares". Hang them into place with the down tubes being mindful of your positioning on both sides ... make sure it is set equal so you wont create a weight imbalance. once tacked in place attach the forward bars that connect to the foot area and watch that you dont crowd the passenger foot area ( if you will ever take passengers). Then measure and build the rear tie bar. Hope this helps, and good luck setting up your bike !
Thank you for the hasty reply, the info will def help
Curious what your welding setup consists of. I was thinking of picking up a rig from Harbor Freight at their next parking lot sale and want to plan what's needed. Can you list all the tools you used including any torches, pipe benders, welding rig, etc? Thanks man. Very great setup BTW
It's now about 10 years later,
in hindsight, what would you do different if you had to redo it?
Honestly not much, they worked well. I Sold this bike, but have a friend who I built a set for that still work well. When I made these there were no real solid options available on the market that were reasonably priced. Recently I purchased another KLR that had the Tusk brand pannier racks and the quick disconnect mounts, they seemed decent for the money and felt pretty sturdy, hard to beat for the price if you do not have access to a welder and shop.
Dude I love your rack hahaha -- seriously super sturdy--- any chance you could upload measurements for the top main rack? where all the holes are and width etc? the one you replaced the plastic top with
Thank you, I wish I had some measurements to give out but I do not have the bike anymore !
What bags do you have and how are they mounted to the brackets.Nice job.
Nice work, well done you :-)
Impressive work there. I like them. Did you build pannier mounts to ?
nice job.
Very nice
How much for the project minus the boxes? Just for tubing and angle material?
Honestly I don't remember exactly. I was getting the metal at cost, about a dollar a foot, 20-30 bucks total. its cheapest to buy it from a wholesaler and buy it in 20 foot sticks. box stores mark it up 100-200%. The rest of the stuff I had on hand so I have no Idea what the out of pocket woud be to buy again, nuts and bolts wise, markup at places like lowes, ace etc is crazy and is as much as the steel.
Looks great
Nice. You should sell them. I'm looking for a good set. How much do they weigh?
how do you fit the boxes to the rack system.nice job
Just ordered some square tubing to make the same rack system you've made. Hopefully mine turns out half as decent as yours look and I'll be happy. Any updates or issues that you've encountered since you've uploaded this video? What plans do you have for panniers? I think I'm going to order aluminum online and weld my own boxes too. I looked online the other night and figured I could make large boxes for almost $100 a piece instead of $300 a piece from some lame business. Ride safe!
great job. subbed
Also, what did you use to measure everything. Thanks!
very good
Watching this in October 2024
nice man
nice job - I would give your vid a thumbs up but from some unknown reason there is not a thumbs up button to click...weird - I love/hate you tube.
what is your tank bag?
عاشت ايدك❤❤❤
Tried to give you a double thumbs up, didn't work so you will have to be satisfied with "Great Job!"
Nice work!
Awesome job.My KLR Brother.