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Message started by Digger on 07/03/10 at 18:19:17

Title: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/03/10 at 18:19:17

Well, I needed a new luggage rack for my Savage (see signature).  I’d been guilty of overloading the trunk at times and the Suzuki rack I had installed when the bike had less than 200 miles on it was showing its age.

The old luggage rack wasn’t cutting it anymore, developing a significant list to port:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/TrunkOnOldLuggageRackE.jpg


(Some of the more observant among you may notice that the subframe is bent a bit on my bike.....I was rear ended a few years ago - twenty-something girl on a cell phone, not paying attention - too bad for me that I did not notice the subframe damage at the time and I let her go).


Here is what the rack looked like with the trunk removed:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-OldE.jpg


Over the years, the welds at both mounting brackets had broken.  I’d had them rewelded, but one side broke again, after the reweld.  The welder said the metal was too thin to do a really good job on.  Here is the side that was rewelded and held:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-OldReweldE.jpg


Here is the side that was rewelded and broke again (notice that the "tab", seen on the side of the rack with the successful weld (above) is missing here):


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-OldBrokenWeldE.jpg


To hold the side with the broken weld in place, I had resorted to u-bolts (note the stress crack in the old luggage rack, caused by the u-bolts):


http://i235.photobucket.com/albums/ee201/Digger109/LS650/U-BoltsonOldLuggageRackE.jpg


Yep, I needed a new luggage rack.

I decided to try the one being made by seviersavage (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1248731274).

We emailed back and forth and I told him that I needed a rack capable of carrying my trunk with two gallons of paint in it.  I placed the order.  Here is what he sent:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewE.jpg


The platform measures 12 3/8” X 8 1/16” and seems to be fairly heavy-duty.  Since it is a cantilever design and I needed something that could carry a heavy load, he modified the mounting area a bit from his standard luggage rack, building in a triangular support section and using four extra bolts:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewMountPointE.jpg


Here are seviersavage’s luggage rack and the OEM luggage rack side by side:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRacks-OldNewE.jpg


Does anyone have any questions?

(Almost – see below) all of the included hardware was stainless steel, including the Nylon insert locknuts.  The nuts and bolts all require a 14mm wrench.  I’m likin’ it:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewHardwareE.jpg


However, he must have run out of stainless steel washers, because one of the sixteen washers he sent (which was larger than the rest) was made of regular old carbon steel:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewRegularSteelWasherE.jpg


Wanting to maintain the stainless steel theme, off to Lowe’s I went.  I bought some 5/16” stainless steel washers (they weren’t cheap) and drilled out  the hole in one of them so that it would fit the supplied 10mm bolts.  Keep in mind that I’m not whining here.  At this luggage rack’s price point, I do not mind supplying a washer, not one bit.

Next, since there were extra mounting holes on my luggage rack, compared with seviersavage’s regular luggage rack, the washers he supplied were a bit too big, causing overlapping:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewOverlappingWashersE.jpg


This would probably not cause a problem, but it was easy enough to rectify the situation.  Out came the old bastard (file):


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewFiledWasherE.jpg


I filed a flat spot on each washer so that they would fit in place with no overlapping:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewNon-OverlappingWashe.jpg


Seviersavage was nice enough to apply these felt pads to the mounting surface:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewFeltPadsE.jpg


Because two of the mounting bolts’ threads would contact the sissy bar posts, I covered the vulnerable areas with a small piece of Ultra-High Molecular Weight (UHMW) polyethylene tape (http://www.mcmaster.com/#uhmw-polyethylene-tape/=7t1njw) to prevent wear spots (no motorcycle workshop should be without this wonderful stuff, BTW).  You can see a small square of the tape on the chrome surface of one of the sissy bar posts here:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewUHMWTapeE.jpg


Here is a look at the mounting bolts after I installed the luggage rack:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewMountingBoltsE.jpg


Pretty stout, I’d say.  The bolts could stand to be 1/8” to 1/4” longer (so that they would thread all of the way through the nuts), but you’d need to install the bolts with the bolt-head pointed forward, instead of aft as I have done.  This is because the rear seat sits right against the nuts as it is.  I oriented the bolts the way I did so that I could get a socket on the nuts easily.

Here is a look at the installed luggage rack:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewInstalledE.jpg


It is very sturdy (I installed the trunk and loaded 2 gallons of milk into it.....the rack handled the load no problem, I’m happy to say).  I did need to make another run to Lowe’s to get some new mounting screws for the trunk platform.  The luggage rack is 1” deep and the mounting screws that came with the trunk were rendered a bit too short to do the job.

It looks a bit utilitarian, but that suits me fine since my Savage is a bit of a pack mule.  If you were to order one and requested that it be only 6” -8” long, I think it would look pretty good.

Overall, I give this rack a solid thumbs-up.  It is perfect for my uses and is simple.  The quality is as good as it needs to be.  A solid and sure-to-be durable addition to my Savage.

Thanks, seviersavage!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by verslagen1 on 07/03/10 at 18:51:50

Was the stock sandwich rack polished stainless steel or chrome plated steel?
The weld that broke lacked full fusion in the center, bad weld.
And you're not supposed to weld chrome.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by jef.savage on 07/03/10 at 18:52:45

Looks good.  I have no problem with function over form.  

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by buttgoat1 on 07/04/10 at 04:19:51

such is life with R&D. there are always minor tweaks to do.
I agree about the smaller size being a better "fit", I would move or modify the rear brakelight for better visability.
all in all, looks good

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/04/10 at 20:13:15


2A392E2F303D3B39326D5C0 wrote:
Was the stock sandwich rack polished stainless steel or chrome plated steel?
The weld that broke lacked full fusion in the center, bad weld.
And you're not supposed to weld chrome.


Chrome plated steel, on the top side.

The underside, where the welding took place, does not have much plating on it.

Keep in mind that the original welds failed before I had the rewelding done.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/04/10 at 20:15:39


687F6C797F787F6C731E0 wrote:
such is life with R&D. there are always minor tweaks to do.
I agree about the smaller size being a better "fit", I would move or modify the rear brakelight for better visability.
all in all, looks good


Am mounting Hyper-Lites (http://www.hyperlites.com/) as we speak.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by seviersavage on 07/05/10 at 10:18:07

Sorry about the one washer that wasn't stainless, not sure how that one snuck in there.

It is a bit utilitarian, . . . .but it should hold up. Glad it's working for you.
Be safe
sevier

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/05/10 at 18:37:03


1310050E03051217090C0C09010D13600 wrote:
Sorry about the one washer that wasn't stainless, not sure how that one snuck in there.

It is a bit utilitarian, . . . .but it should hold up. Glad it's working for you.
Be safe
sevier


Thanks, sevier.  I'm very pleased!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/05/10 at 18:40:07

I made one other small mod I should mention.

I zip-tied a piece of old leather in front of the mounting plate to keep the mounting nuts from possibly wearing into the aft portion of the rear seat cover:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewSeatProtectorE.jpg


If I'd positioned the nuts facing aft, I wouldn't have had to worry about it.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by cursal on 07/06/10 at 06:43:40

looks real sturdy. Great addition to the "pack mule"  and even better seeing SuzukiSavage.com doing biz with one another :)

I love this place!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/08/10 at 08:19:47


270A04040611630 wrote:
[quote author=687F6C797F787F6C731E0 link=1278206358/0#3 date=1278242391]such is life with R&D. there are always minor tweaks to do.
I agree about the smaller size being a better "fit", I would move or modify the rear brakelight for better visability.
all in all, looks good


Am mounting Hyper-Lites (http://www.hyperlites.com/) as we speak.[/quote]


Hyper-Lites are installed.  See here (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1278562220).

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Joe F on 07/08/10 at 16:53:50

I like the fact that the bracket is up an inch or so from the normal one.  That moves it away from the brake light and might make the light more visible.

Of course the hyperlites help a bunch with that.  8-)

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by sparky380 on 11/13/10 at 08:10:35

Why not just make the holes in the flat bracket plate square with a Dremel tool and use stainless steel carriage had bolts instead?

Bill

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by justin_o_guy2 on 11/13/10 at 09:00:20

A carriage bolts Square Hunk can be rounded off pretty easy on a grinder.


Digger, you FILED all that? A 4 & 1/2" grinder can be fixed up to use a cut off disk. That, along with another grinder with grinding disk & a vise & you can cut your labor time waaaay down.
W/ regard to buying the consumables, Harbor Freight may be cheap to pay for, but their cutting/grinding disks go away fast & buying a better quality pays off.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 11/16/10 at 21:37:58


233C3A3D20271626162E3C307B490 wrote:
A carriage bolts Square Hunk can be rounded off pretty easy on a grinder.


Digger, you FILED all that? A 4 & 1/2" grinder can be fixed up to use a cut off disk. That, along with another grinder with grinding disk & a vise & you can cut your labor time waaaay down.
W/ regard to buying the consumables, Harbor Freight may be cheap to pay for, but their cutting/grinding disks go away fast & buying a better quality pays off.



Jus,

You're right, no doubt.

However, the stainless steel filed pretty easily.  Even I (and, I am lazy) did not find the job to be burdensome.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 11/16/10 at 21:40:17


2E2D3C2F36246E656D5D0 wrote:
Why not just make the holes in the flat bracket plate square with a Dremel tool and use stainless steel carriage had bolts instead?

Bill



Spark,

Good idea.

I did not think of it at the time.  But, even if I had, I would probably have passed on it, as I am way too lazy.   :)

Thanks!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by justin_o_guy2 on 11/16/10 at 21:52:54

I think itd be easier to round off the corners on a carriage bolt than drill a square hole.  A slot if it must be backed up to get it tight would still take less time than trying to create a square hole.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 11/18/10 at 21:23:59


4E636D6D6F780A0 wrote:
[quote author=2E2D3C2F36246E656D5D0 link=1278206358/0#12 date=1289664635]Why not just make the holes in the flat bracket plate square with a Dremel tool and use stainless steel carriage had bolts instead?

Bill



Spark,

Good idea.

I did not think of it at the time.  But, even if I had, I would probably have passed on it, as I am way too lazy.   :)

Thanks![/quote]


To expand on this, I believe Sparky was referring to this small mod I made to protect the aft face of the rear seat from damage:

--------------------------------------------------------------------------------

I made one other small mod I should mention.

I zip-tied a piece of old leather in front of the mounting plate to keep the mounting nuts from possibly wearing into the aft portion of the rear seat cover:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRack-NewSeatProtectorE.jpg


If I'd positioned the nuts facing aft, I wouldn't have had to worry about it.

--------------------------------------------------------------------------------


I must say, in Sevier's defense, I believe he intended for the bolt-heads (vice the further-protruding nuts) to be facing toward the front of the bike.  Oriented in this fashion, I don't believe that fouling the aft-facing surface of the rear seat would be a problem.

I faced the bolt-heads aft and the nuts forward because the nuts were easier to tighten that way and I was too lazy to orient the bolts properly.

Clear as mud?

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 08/10/11 at 19:34:27

An update on this luggage rack:

Last April, I was running errands and noticed that my trunk (mounted on the luggage rack) was starting to flop around.  I stopped in a parking lot and looked the situation over.

A weld on the luggage rack had given way:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackFracture-1E.jpg


Note:  The above picture was taken after I had removed the trunk.

Here is a closeup look at the weld that failed:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackFracture-2E.jpg


Also, I was dismayed to find that the weld's twin, on the other side of the rack, was showing signs of imminent failure:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackCrackE.jpg


Well, I was several miles from the barn and it was clearly unsafe to continue riding the bike in this condition.  So, I removed the trunk from the rack and bungeed said trunk to my rear seat.  Boy, was I ever glad that I had made a quick-disconnect for the trunk's wiring harness (see this thread (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1278562220)):


http://i235.photobucket.com/albums/ee201/Digger109/LS650/Hyper-Lites-ConnectorE.jpg


That saved me from having to rip the wires in order to get the trunk off of the luggage rack.....and creating a lot more work down the road as a result.

I emailed seviersavage (http://suzukisavage.com/cgi-bin/YaBB.pl?action=viewprofile;username=3033262D202631342A2F2F2A222E30430) to ask his advice.  I wasn't looking for a refund or a freebie, just advice.  He responded and said he'd never seen such a problem develop with any of his racks.  I gave him a few suggestions for ways he might possibly beef up any luggage racks he makes in the future.  He was very pleasant.

In any event, I still had a broken luggage rack.....and my Savage is my daily driver (I don't own a cage).  I had to get creative.

Well, I found two stout little angle brackets in my spares bin.  I drilled a few holes in the luggage rack and installed the brackets.  I think this will last a while:


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackFix-1E.jpg


http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackFix-2E.jpg


Bottom line:  I'm still pleased with my luggage rack!


BTW, any thoughts on my amateur "repairs?"






Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Boule’tard on 08/10/11 at 19:56:20

I agree that the repair should last a while, but I'dve used it as an excuse to buy a little stick welder and a few pieces of scrap to practice on.  On that particular rack, you can get at the weld from both sides, making the job very easy.  If it breaks again in that spot, you could fix it up without having to become an expert welder.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Grand Strand on 08/10/11 at 19:59:53


7F72687178697C6F791D0 wrote:
I agree that the repair should last a while, but I'dve used it as an excuse to buy a little stick welder and a few pieces of scrap to practice on.  On that particular rack, you can get at the weld from both sides, making the job very easy.  If it breaks again in that spot, you could fix it up without having to become an expert welder.


+1 Its a great first project! I love more tools  :)

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by dekuji63 on 08/18/11 at 22:16:21

Really enjoying going through this thread - sorry about the rack break, though.  It really looks sturdy but the stress on those attachment joints must be pretty high.

I'd like a similar one only wider rather than longer.  I bought a tail bag (Nelson Rigg) and I hate the attachment for it.  Plus it's ginormous and sags down over my tail light so now it's my pillion rider.  ;D  I was just thinking about finding a beater trunk, hacking off all but the bottom and using it as a plate to hold my saggy bag up.  Sevier's rack looks much nicer!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Sunchasers on 08/19/11 at 00:14:37

Digger... I think your "patch" looks strong enough and on the right track for a better attachment solution.  Since you didn't mention what suggestions you had already made to the builder, here are a couple of thoughts that came to mind after looking at your latest pics...

My first thought would be to make the back "strap" bracket  longer and "l_____l" shaped with the legs 2-3" long or just long enough for a couple bolts on each side.  The legs could be bent (or welded) and profile cut to match the side rails of the rack bed.  This should essentially double the strength of that joint on both sides.

Second thought would be to just weld a peice of angle to the inside for addtional joint reinforcing or welding a couple of gusset plates on top at each back corner (also on the bottom if you can work around the side rail profile).

Just my 2 cents....  :)  Please keep us updated on your progress, I am interested in doing something like this too!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 08/21/11 at 18:33:09


37213A3036530 wrote:
.....My first thought would be to make the back "strap" bracket  longer and "l_____l" shaped with the legs 2-3" long or just long enough for a couple bolts on each side.  The legs could be bent (or welded) and profile cut to match the side rails of the rack bed.  This should essentially double the strength of that joint on both sides.....



Sun,

Thanks for your insight.

Although my jury-rigged fix doesn't worry me and seems quite strong, I think a better solution (for someone who doesn't know how to weld :-[) would have been longer angle brackets that bolt to the "strap" bracket you speak of.  The rear parts of said angle brackets would have still been bolted to the body of the rack, as I have done with the short angle brackets I used in the above pics.

I may have gone the way I did because, like I said, I already had the short brackets in my spares bin.....and I was probably too lazy to ride the three miles to Lowe's.   :)

Perhaps seviersavage will see this thread and get some ideas!

No worries!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Michael A.N. Winkler on 02/20/12 at 11:30:54

Good Afternoon All:

Does anyone know whether the "SevierSavage's" luggage rack is still available for a LS650P Savage built in 2003?  

And if not, would anyone know of a good substitute?

Thank you for your help (I am new to this site and to the "savage").

Michael
manwinkler@yahoo.com

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 02/20/12 at 16:30:55


2F3C2B2A35383E3C3768590 wrote:
Was the stock sandwich rack polished stainless steel or chrome plated steel?
The weld that broke lacked full fusion in the center, bad weld.
And you're not supposed to weld chrome.

I've had TWO Suzuki racks and BOTH broke at the welds.  Now I have this one from Scootworks.com.  The rack is part of the sissy bar and is not detachable.  I've only had it a few months, so I can't say for sure it's any better than stock but it appears to be better construction.  I'll remove my bags from it and take a couple of pics a bit closer up.  Below is the image (hotlinked) at Scootworks.

http://www.scootworks.com/swcart/shop/roncar/savage.jpg (http://www.scootworks.com/shop.cgi/page=partssuzsissy.htm/SID=PUT_SID_HERE)


Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 02/21/12 at 15:53:18

Okay, a few pics...

Here you can see the general design and the welds.
http://farm8.staticflickr.com/7045/6918940943_d50391cdef_b.jpg

That disc-looking thing is a rare-earth magnet I once used with my oil filter but now use to temporarily hold tools and such.
http://farm8.staticflickr.com/7199/6918940987_b211b1f2bc_b.jpg

Wow!  This came out a little oversaturated but the intent was for you to see the pad.
http://farm8.staticflickr.com/7201/6772825536_803ab105c9_b.jpg

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Joe F on 03/31/12 at 19:11:22

Thanks for the pictures.  It looks nice. The rack looks a little higher than the stock?  Is that true?  It might make the brake light more visible.  

Still no good way to mount a top case :-(

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Joe F on 07/09/12 at 03:52:33


5F6D7A6D6B69535E636E0C0 wrote:
I've had TWO Suzuki racks and BOTH broke at the welds.  


I broke the welds this week on another of the OEM racks.  I keep staring at them thinking the way to solve the problem is to drill two holes from the side of the rack through the sissy bar.  Then I could bolt the rack to the bike from the side rather than relying on the cheap metal bending approach taken by the OEM rack.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 07/09/12 at 14:36:48

So far as the height difference, I'll have to dig out a stock one and compare.  I think you're right that it's a bit higher but I'm just not positive.  The overall sissy bar is a bit taller for sure, though not as tall as I'd like it to be.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by High_Plains_Thumpr on 07/10/12 at 00:49:26


153836363423510 wrote:
An update on this luggage rack:

Last April, I was running errands and noticed that my trunk (mounted on the luggage rack) was starting to flop around.  I stopped in a parking lot and looked the situation over.

A weld on the luggage rack had given way:

http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackFracture-1E.jpg
SNIP

Bottom line:  I'm still pleased with my luggage rack! BTW, any thoughts on my amateur "repairs?"

You have a tremendous amount of stress on that very small cross section to support the trunk. This amount of stress is increased tremendously when the motorcycle continually bounces along the uneven road surfaces. You basically have cyclic fatigue going on.

A simple solution would be to extend metal brackets (see picture) as diagonal braces from the pillion handle or rear of the fender area to a location toward the rear of the package rack. This was common in earlier motorcycles and it work. It will offload the tremendous bending moment you have on the smallish weld area.  ;)

http://highplainsthumper.pcriot.com/LuggageRackBrace.jpg

Here is a possibility for brace material:

http://www.homedepot.com/Tools-Hardware-Hardware-Metal-Stock-Bar-Flats-Tubes-Rods/h_d1/N-5yc1vZc2gt/R-202183487/h_d2/ProductDisplay?catalogId=10053&langId=-1&storeId=10051

or http://tinyurl.com/6v7f9r2

YMMV.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by rfw2003 on 07/10/12 at 01:17:58

After reading through this thread, with me thinking about getting a luggage rack for mine,  I'm leaning towards making my own now. Just do away with the stock Sissy bar itself and do the whole sissy bar and luggage rack from scratch with diagonal supports on each side.  Plus doing it this way I could make the Sissy bar with back rest taller for more support for my kids when I give them rides,  Might even be able to come up with a way to put in a back rest for myself doing it this way for those longer rides as well.  This might be the only way to get rid of the breakage issues I'm reading about in this thread from the OEM and aftermarket ones.

R.F.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by High_Plains_Thumpr on 07/10/12 at 01:23:56

Highway Hawk, Netherlands used to make a Savage package rack. I am glad I picked this one up, unfortunately it has been discontinued for a while.

It has solid plate steel that bolts underneath the pillion handles and continues rearward, is tremendously strong.

Good luck on all those for overcoming the lack of a decent package rack.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 07/31/12 at 21:43:53


16373936010E323F37302D010A362B332E2C5E0 wrote:
[quote author=153836363423510 link=1278206358/15#18 date=1313030067]An update on this luggage rack:

Last April, I was running errands and noticed that my trunk (mounted on the luggage rack) was starting to flop around.  I stopped in a parking lot and looked the situation over.

A weld on the luggage rack had given way:

http://i235.photobucket.com/albums/ee201/Digger109/LS650/LuggageRackFracture-1E.jpg
SNIP

Bottom line:  I'm still pleased with my luggage rack! BTW, any thoughts on my amateur "repairs?"

You have a tremendous amount of stress on that very small cross section to support the trunk. This amount of stress is increased tremendously when the motorcycle continually bounces along the uneven road surfaces. You basically have cyclic fatigue going on.

A simple solution would be to extend metal brackets (see picture) as diagonal braces from the pillion handle or rear of the fender area to a location toward the rear of the package rack. This was common in earlier motorcycles and it work. It will offload the tremendous bending moment you have on the smallish weld area.  ;)

http://highplainsthumper.pcriot.com/LuggageRackBrace.jpg

Here is a possibility for brace material:

http://www.homedepot.com/Tools-Hardware-Hardware-Metal-Stock-Bar-Flats-Tubes-Rods/h_d1/N-5yc1vZc2gt/R-202183487/h_d2/ProductDisplay?catalogId=10053&langId=-1&storeId=10051

or http://tinyurl.com/6v7f9r2

YMMV.[/quote]


That's a decent suggestion, thanks.

The small 90 degree steel braces (see my post on the second page of this thread) have turned out to be quite strong, it seems to me.  However, if I encounter future problems, I'll consider these side braces.

They would, however, require a bit of disassembly, as I'd need to put nuts in the inward facing sides of those chrome-plated rear fender struts.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by greenmonster on 07/31/12 at 22:32:38

Savage Rob - Which model is that sissy bar/luggage rack that you have? It looks like it's what I want. I like how it appears to be a little higher over the tail light, than the stock rack.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 08/01/12 at 16:37:29


564354545F5C5E5F42455443310 wrote:
Savage Rob - Which model is that sissy bar/luggage rack that you have? It looks like it's what I want. I like how it appears to be a little higher over the tail light, than the stock rack.

It is a bit higher than the stock.  The image in the previous post by me was hotlinked to the seller's site.  It looks to me like Scootworks no longer sells this item but they have two other versions for the Savage/S40 available.  Both are shown on the page if you scroll down.  One has a studded pad and the other is plain.  I don't know if what I got is available anywhere now since Scootworks was the only place I ever saw it.  Both images are hotlinked to the same location.  I did see some pictured further down the page that resemble mine but did not see if any fit the LS650.  You might call them to find out.

This is what I got:

http://www.scootworks.com/swcart/shop/roncar/savage.jpg (http://www.scootworks.com/shop.cgi/page=partssuzsissy.htm/SID=PUT_SID_HERE)


This is what they show now:

http://www.scootworks.com/swcart/shop/cwi1/s_03-246.jpg (http://www.scootworks.com/shop.cgi/page=partssuzsissy.htm/SID=PUT_SID_HERE)

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by greenmonster on 08/01/12 at 18:47:54

Darn, the one that scootworks has now is a little more than I want to spend. I guess the search continues.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 08/02/12 at 14:50:26


2E3B2C2C272426273A3D2C3B490 wrote:
Darn, the one that scootworks has now is a little more than I want to spend. I guess the search continues.

Seriously, scroll down the page a little further and they describe some with round bars that resemble what I originally bought from them.  It can't hurt to give them a call and ask whether any are available for the LS650 and, if so, at what cost.  They still look pricey when all parts are considered but it can't hurt to ask.  I hope you can find a similar one.

I had been searching for the Highway Hawk model mentioned earlier in this thread because I'd remembered seeing it several years before but was unable to locate any.  Take a peek at eBay every now and then.  You never know what somebody will get tire of and take off.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 08/06/12 at 19:34:20

What we really need is for someone here on the board who welds to take up where seviersavage left off, building luggage racks.  With a few small changes, his design would be totally solid right out of the box....

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by CalisOsin on 08/07/12 at 11:14:49

My brother is a welder. He works on bikes and has been thinking about building some sort of custom part to sell. I'll pitch the idea to him. What modifications would you all make to seviersavage's design to make it perfect?

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by greenmonster on 08/07/12 at 11:52:10

I've spoken with one of the welders that I work with. I'll be drawing up a design and giving it to him to weld up for me. I want it out of stainless and I only have MIG here or I'd do it myself.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Digger on 08/08/12 at 20:28:30


6644494C566A564C4B250 wrote:
My brother is a welder. He works on bikes and has been thinking about building some sort of custom part to sell. I'll pitch the idea to him. What modifications would you all make to seviersavage's design to make it perfect?



Maybe a little bit beefier bar stock, with a reinforcement (perhaps a section of angle stock) welded to the inner sides of the two corners where the welds broke on mine.

To me, strength is more important than looks, but I don't want it to get rusty over time, either.....

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Joe F on 08/09/12 at 04:07:08

Here's how I hacked up the OEM rack after breaking another set of welds.
http://3.bp.blogspot.com/-G-NIYZrvbMk/UCMZtPn6vVI/AAAAAAAAAWs/KTWKq7xLcl8/s200/DSCN2291.JPG I drilled a couple holes through the rack and sissy bar and then re-used the rack bolts.  

http://joe-freeman-personal.blogspot.com/2011/05/suzuki-s40.html

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by ZAR on 08/09/12 at 07:02:35

Nice mods Joe!!!

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 08/09/12 at 10:59:12

That seat looks interesting.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by greenmonster on 08/16/12 at 15:09:10

Got the call, my rack is ready to be picked up. I'll try to toss some pic's up tomorrow night. And I have a trip planned for the Sept long weekend so we'll give her a test then and I'll let you know how it works out.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by Savage_Rob on 08/16/12 at 15:27:27

Looking forward to seeing it.

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by arteacher on 08/16/12 at 16:08:28

Raask makes a nice one.http://www.raask.se/ind-eng.htm

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by OdysseusNY on 03/27/14 at 14:36:39

Bump.

For anyone else searching, there is a new rack (from hong kong) on ebay here: http://www.ebay.com/itm/310439820076?item=310439820076&frommaketrack=true&viewitem=&vxp=mtr (in case that link dies, search for seller "dream6625" and item "Backrest Sissy Bar Suzuki Savage LS400 LS650 87-97 #r" they also have a few other sissy bars but only one with a rack, which is the #r part)

I might pick it up and if so will report on its quality. Just emailed the seller to verify the rack and the bar come together for that price (~ $140 USD shipped) and a few questions about installation details. There are no current reviews of this item although I found one good ebay feedback (and no neg) on one of the other s40 sissybars with similar mounting (but no rack).

Also to add regarding the raask rack, I contacted them and want to mention the staff (Sivert) was very good about responding to my request and providing information. According to him, some countries had slightly different bikes and his carrier didn't fit there, I wasn't confident enough judging from the pics to buy one (the screw holes looked a little different from what is shown in my repair manual) but I encourage anyone who is looking for a rack to at least check them out because again his email support was very good. They are Sweden based.

At this point I'm thinking either that ebay one or the OEM (despite the weak weld reports, I'll just avoid heavy loads). If anyone knows other new options or has tried that one from ebay, info would be appreciated. It's unfortunately the OEM model seems so weak.

Attached a picture of the ebay rack. I'm wondering if it goes under the stock chrome piece that would be in that area, or just replaces it (which might not look very good). The OEM sissybar replaces that part but has identical styling, whereas this one is very flat. Thoughts?

Title: Re: Product Review - Seviersavage's Luggage Rack
Post by OdysseusNY on 05/07/14 at 15:48:21

An update on the ebay item I mentioned in the previous reply. I decided to buy it. So far I'm very happy. I think the total with shipping from Asia to NYC was ~135 USD. Pictures at: http://imgur.com/a/mNhRZ

The only drawback is that it's not compatible with the stock chrome side handles that are on the rear fender, assuming you have the same ones I did (they are shown in one of the pictures linked). This also means it's probably not compatible with the stock rear turn signals (although I'm not 100% sure on that since I had already changed mine to aftermarket).

The side handles are mounted using nuts and bolts on 4 holes that are on the fender. This item basically mounts using two of those same holes. I didn't install myself, since I had to drop my bike off at the shop for inspection and some other odds and ends, but I don't think it would be very difficult if you're handy. The hardest part might be the rear turn signals, as you'll need to reroute the wires and probably buy different signals. We routed the wires under the seat, with just a little bit of wire sticking out to where we stuck the signals onto the rack.

I was willing to sacrifice my side handles, since they were basically obscured by my saddlebags anyway. There are two holes in the fender left unused which also might bother you. I just stuck a plug in one and the extra nut and bolt in the other on each side.

I haven't put anything too heavy on it yet but it seems sturdy enough for my needs (laptops, clothes, some groceries, etc).

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