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General Category >> Rubber Side Down! >> Check out my new (temporary) custom cargo rack.
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Message started by och on 01/05/22 at 15:41:26

Title: Check out my new (temporary) custom cargo rack.
Post by och on 01/05/22 at 15:41:26

So this is used to be the cargo setup on my S40, I just took it off and it's up for grabs in the marketplace forum. It was basically stock saddle bags with supports and rails, stock passenger backrest, and a bent stainless steel cargo rack with a small bicycle trunk. It was decently practical, but I did not love it, so off it goes.

http://https://i.imgur.com/u56TfrH.jpg

http://https://i.imgur.com/625fwN8.jpg

So now the story will get a little bit long, but it kind of has to. Besides the S40, I also have a V Star 950, and I take that bike for long trips with my wife, so we need to be able to carry a lot of stuff. I bought two large Viking saddlebags for it, and a genuine Harley King Tour-Park. The tour pack alone fits two full size helmets with room to spare, and then there is a bunch of room inside the saddle bags, now we can really carry a lot of stuff.

However the stock cargo rack was far too small and flimsy to properly mount the gigantic tour pack, so I researched and found a company called Wompus racks. They sell custom made heavy duty racks, and I ordered one. It worked much better than the stock rack, but I did not love it. It was made from light gauge steel, with a black powder coat finish, and it was welded out of three pieces, and fitment wasn't perfect.

http://https://i.imgur.com/3bJ6aLC.png

So I decided to make one myself. I had it laser cut out of full 1/8" thick 316 stainless steel, and brake formed instead of welded, with base and all the mounting holes to specifically alight with the tour pack. It worked out great - perfect fit, solid, stainless steel for corrosion resistance, and simple to mount with just four bolts.

http://https://i.imgur.com/U9ttohF.jpg

http://https://i.imgur.com/K0larUi.jpg

However when I was laser cutting it, I had a leftover sheet of stainless that would otherwise be waste, but it fit the template to make 2 racks... so I made two of them and one was just sitting in my garage collecting dust. So earlier today, I said let me try something - put it against the rear fender of my S40, and it looked like it would fit.

So I took off all the stock stuff, and had it mounted. It fit, but obviously not too well. It is way to low, with the base almost resting on the tail light, and blocking its view, and the base is lower than the seat.

I will order a new trunk, when I decide which trunk I like, and I will then determine the exact size of the base and the risers, and cut a new rack. Meanwhile, check out the photos - it is much lighter than the stock junk, much stronger, and much easier to install with just four bolts.

http://https://i.imgur.com/ZiTQ0Pa.png

http://https://i.imgur.com/Ewx0Hvc.jpg

Title: Re: Check out my new (temporary) custom cargo rack
Post by TheSneeze on 01/05/22 at 17:04:15

Nice piece of sheet metal work there! I like the brushed finish.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/05/22 at 17:13:17

Yep, I could do polished as well, but its much more expensive, I'm not buying a 4x8 sheet just for that. I can polish it to mirror finish by hand, but thats just too much work.

Title: Re: Check out my new (temporary) custom cargo rack
Post by Evanswv on 01/05/22 at 18:50:11

Looks real good.

Title: Re: Check out my new (temporary) custom cargo rack
Post by Tocsik on 01/06/22 at 14:59:04

How about mounting low-profile brake and turn signal lights on the trunk and not worrying about raising it? Or do you want the on/off option to be clean? You could mount lights on the box with a quick disconnect and leave the stock lights on the bike, too. If everything is LED, the bike's meager charging system can probably handle it.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/06/22 at 19:35:11

073C30203A38530 wrote:

Well, a few things. First, I don't want the trunk to project far out of the bike, I am actually waiting for the trunk to arrive so I can measure it up against the bike so see how it fits, and I am thinking of installing it over the passenger portion of the seat. It will essentially make the bike only possible to ride solo, but I always ride solo, so its fine. Plus I sit far back on the seat, half way onto the passenger portion, and the backrest of the trunk is going to be rider backrest.

Second, I really don't want to put any lights onto the trunk. It is a nice leather wrapped trunk, any lights are going to look out of place, so I am designing the cargo rack in such way where it wont block the lights.

And finally, when it comes to turn signals, I don't know yet what I am going to do. I may install them onto the new rack, more or less like they came from factory, or I may relocate them onto the license plate.

Title: Re: Check out my new (temporary) custom cargo rack
Post by SoC on 01/06/22 at 20:37:39

Nice work, but I have to say that the seat might be the most comfortable looking I have ever seen on one of our rides.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/06/22 at 20:57:22

4A4B4E5C5F5C534E56543D0 wrote:

Nice work, but I have to say that the seat might be the most comfortable looking I have ever seen on one of our rides.

It is a Corbin seat, modified - stuffed with foam to make even height across the rider and the passenger portion. Being 6'4", I used to ride on the passenger portion of the seat before I had the seat modified. ;D

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/07/22 at 05:10:48

Just did a rough sketch to visualize what I plan on doing. This is on a photo of a stock S40 that I found, mine is different since my seat is the same height across the whole length.

http://https://i.imgur.com/VK11YvZ.jpg

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/07/22 at 10:31:42

And just for shits and giggles, this is my riding position on the bike. ;D ;D ;D

http://https://i.imgur.com/m8xkr7r.png

Title: Re: Check out my new (temporary) custom cargo rack
Post by Evanswv on 01/08/22 at 15:18:05

[quote author=58545F370 link=1641426086/0#9 date=1641580302]And just for shits and giggles, this is my riding position on the bike. /quote]
My Savage has the same seat as the one you have pictured, and that's about how I fit. I think I may be a little tall for the bike, and wonder if I look funny, but really don't care. I can ride properly seated, and may take the rear cushion off, and make a rack that utilizes the standards for the sissy bar (which the guy that I got the bike from is supposed to look for), and mount a decent trunk.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/09/22 at 19:50:16

The Viking trunk came in today, I test fitted it, it looks great!

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 01/13/22 at 16:18:24

I sent my seat to Russell Cycle Products to get properly redone. I the meantime, I made a cardboard template of the rack, waiting to get the seat back before I laser cut the stainless. Want to make sure the dimensions are good.

http://https://i.imgur.com/dDjfeWk.jpg

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 02/22/22 at 14:48:29

Ok, so I now go pretty much everything to complete it.

Seat redone by Russell Cycle.
Viking Bags leather top case
Stainless cargo rack
Eight grade 9 bolts, 3/8"-16 x 1-1/2", with washers, distorted thread nuts, and 3/4" stainless steel spacers.
Harley turn signals with Kuryakyn Tracer diffused LED inserts

So far I have only installed the seat, its raining and nasty outside, if it stops raining I will go out and try to install the rack.

http://https://i.imgur.com/I5bPhpe.jpg

http://https://i.imgur.com/SFzrVLT.jpg

http://https://i.imgur.com/uziAAiJ.jpg

http://https://i.imgur.com/3VtLjoh.jpg

http://https://i.imgur.com/tJXCxMR.jpg

http://https://i.imgur.com/bZHO676.jpg

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 02/22/22 at 16:29:24

As if I have the patience for this rain nonsense. Went out and installed the rack and the turn signals. Will try and get the top case in tomorrow.

http://https://i.imgur.com/CCgOPMS.jpg

http://https://i.imgur.com/Yl7d0aa.jpg

http://https://i.imgur.com/lBIhsXp.jpg

Video in the link below, shows off the turn Tracer turn signals. They are ridiculously blind, I might do the same conversion for my front signals as well. In the front I have Sylvania Zevo LED bulbs, they are about the same brightness as stock halogen.

https://youtu.be/4Gm9TK5ZbX4

Title: Re: Check out my new (temporary) custom cargo rack
Post by verslagen1 on 02/22/22 at 16:46:17

Once I got rear ended.
Shot me straight back flat against his grill.

Looking at that makes me wonder how much would get shaved off. :o

I think I would weld a bar along the front as it's too late for a dutch bend.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 02/23/22 at 10:42:22

https://www.youtube.com/watch?v=yWJjDkjY6n0

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 02/23/22 at 10:45:55

Finally finished.

http://https://i.imgur.com/Ps2sFKy.jpg

http://https://i.imgur.com/SsL4EjK.jpg

http://https://i.imgur.com/jtoxhoD.jpg

http://https://i.imgur.com/jRyqsI4.jpg

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 02/23/22 at 11:12:27

http://https://i.imgur.com/TxHd8Y0.jpg

Title: Re: Check out my new (temporary) custom cargo rack
Post by badwolf on 02/23/22 at 16:43:51

That looks HUGE! Very good job. Does your back rest against it, or just for the passenger? Post a pic of you sitting on it.
I see you have gone to a led headlight, good move. Did you find a bulb that fit in the stock can, or did you have to get a new one? People ask about that every month or so it seems.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 02/23/22 at 19:44:26

6466756B75776F666E75070 wrote:

Yes, my back rests on the backrest - I sit further back on the seat. The rack and the trunk are actually partially over the passenger portion of the seat, so effectively this is now a solo setup. This is a photo of me on the bike prior to redoing the seat and the trunk.

http://https://i.imgur.com/PCOycnA.png

The LED headlight is the Denali M5 with mounting bracket, and the passing lights are LED from Show Chrome, and I made custom brackets to mount them. It is much better that putting a LED bulb into the stock housing.

http://https://i.imgur.com/3OOyMQI.jpg

http://https://i.imgur.com/Oz8BRxw.jpg

There is also the new "Retrobright" headlight from Holley, they look like regular halogen housings, but they are LED, and even come in warm white color - look period correct on older cars and bikes, but 5x brighter than regular halogen.

https://www.holley.com/products/exterior/lighting/headlight/round_headlights/parts/LFRB125

Title: Re: Check out my new (temporary) custom cargo rack
Post by justin_o_guy2 on 03/05/22 at 14:07:26

Nice! Great color scheme. Got down to a good look at the seat,, thought
I couldn't get a foot down, dude must be pretty big.
Next picture
Yep,big dude!

Och,,is that like a talisman? Does it help keep U out of Ouch?

Title: Re: Check out my new (temporary) custom cargo rack
Post by DragBikeMike on 03/05/22 at 16:18:23

OCH, you did a sweet job setting that scooter up just perfect for you. Very sano too. Like a factory install. You are one BIG dude. I suspect that saddle and backrest make the Savage way comfier.

I am impressed with the landscaping around the house. Do you do your own landscaping? Beautiful.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 03/06/22 at 21:37:58

647B7D7A6760516151697B773C0E0 wrote:

Haha, yeah, I'm 6'4, right now about 230lbs, although my weight fluctuates between 200-250 depending if I get in or out of shape.

Och is just an abbreviation of my old childhood nickname.

Title: Re: Check out my new (temporary) custom cargo rack
Post by och on 03/06/22 at 21:40:54

1E18176B696E6A5A0 wrote:

Thank you, it has definitely made the bike a lot more comfortable for me, and also a lot more practical. Now I can actually carry a decent size shopping or whatnot.

My wife does the landscaping, and she takes a lot of pride in it.

Title: Re: Check out my new (temporary) custom cargo rack
Post by justin_o_guy2 on 03/06/22 at 23:43:01

She should be pleased..