My touring bike (now over 26 years old) was in need of some TLC. The transmission was worn out, the Campy ergo levers on their last legs and the rims about to explode, so a re-vamp was in order.

It doesnt do big tours any more and just carries a rack pack. The Tubus rack is a bit of overkill and quite a lump so I decided to build a light weight rack specifically for the rack pack - and to include a pump mounting to save space in the pack.

I used 10mm x 0.9mm wall chromoly and the finished rack came out at just over 400g. It is solid as a rock and could certainly carry full panniers at a push. With hindsight I would have used thinner wall tube (10mm x 0.5mm) but this is no lightweight racing machine so not too bothered.

It is quite easy to do with a few basic tools and a gas torch. MAP gas is sufficient for these small tubes though Oxy/Propane or similar would make it easier. Just take care not to burn your bike - I did manage to melt the mudguard a little :-(

Cool project but not sure how you burned your bike or melted anything? Surely you didn't just torch it on the bike with everything mounted?