luggage rack fab

[davipu]

electrical metal tubing  otherwise called thin wall conduit  learn by doing, that is the most fun way
if you can find 1/2" stuff I have a bender you can barrow

[smoker]

I actully planned on using conduit (part time electrician with friends in the biz with benders galore, but thanks for the offer Davipu), but never heard it referred to as anything other than conduit.  But then again, southwest PA is the Kentucky hills (no offense, Kentuckians; you've got a beautiful state) of the north, most real names for things rarely get used.  

PS  Thanks to all for making this my first two-pager!!!

[luksi]

Here's my homemade EMT rack before grinding down and painting.  I used a sledge hammer and concrete step to form the flat areas and the connection to the bike (a flat piece welded on bottom holds the bends onto GS frame).  


The downtubes connect to brackets (part A) on each side that I hammered out and attached much like the 5 star model shown on Kerry's page.


I didn't use a pipe bender as you can buy prebent Ls or 90s with connectors.  The connectors have screws to hold them in place.  Very helpful in fitting/sizing.  I removed screws once the connectors were welded together.  Stainless steel bolts and lock nuts hold downtubes to rack and frame.


I don't know if JB weld would work with the connectors.  Someone might try.   I had access to welding equipment but you must be careful as it's easy to burn through the thin walled EMT.  I filled in the holes with some spare bondo before painting.

[smoker]

Dude, that diagram was exactly what I wanted to see!!   Nice job on your rack, by the way.  I'm pretty handy with a MIG, but understand about the thin wall stuff burning thru...  Low current, low feed rate, go SLOW...  But then again, I do love the bondo (makes up a fair percentage of my '93 F-150).  Thanks again, all!!!!