Hi thanks for asking.
I made all the attachment stuff out of hardware store aluminum, flat and round stock. The type you see in bins at Lowes etc. it comes in 4 and 6 foot lengths. I picked the material and also the process so that it would be well suited for touring, if something breaks on the road it wouldn’t be hard to make a repair and bolt it back together. I also tried to do things in a way just about anyone slightly handy could copy without special tools. You will need a hacksaw and a file and a bench vice, hammer and scraps of wood.
All the cuts were made with a hacksaw and the free end was left long to have something to lever against and then trimmed after the bends were made. I cut a scrap of wood to act as a form rounded the corners and then sandwiched the aluminum between the form block and a scrap block so the vice wouldn’t cut into the softer material. I then hammered it around the corner and trim it off while it’s still clamped.
Things like the bag hook were made from 1/4 rod two bends to make a “C” shape then I clamped that in the vice to a broom handle and made the two hooks and trimmed them. The whole thing then slipped thru the belt strap thing on the camera bag. That little bag facing the rider is great and doesn’t seem to get in the way riding. I like to use the front rack for my Military Sleep System to strap to and a normal front bag would take up that space. The MMS is not heavy, more bulky so it’s perfect up front.
Some of the stuff that had to be a little stronger I use ether 5/16 or 3/8 round rod and bend as above and then flatten the ends in the vice or you can do it by forging it cold with a hammer against the vice top like an anvil. Most of the bolts on the bike are 5mm so smashing it about 50% allows a wider area and a flat surface to drill a mounting hole thru.
The front rack was an experiment in using the 1/8 x 3/4 strip aluminum. It’s really easy to work with and that rack is way stronger than need be, and not that heavy. It now has a double front stay (will attach a picture) and I could give a person a lift on it I think.
I have plans on changing the front rack a little and building a mate for it as a rear rack. I hope to find the time to do that this summer. No real reason other than to say I made the rear rack and have them look like a set.
Hope this helps you out and when I build the rear rack I will try and remember to take a few photos.
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