Hi, everyone. I know how to weld steel, MIG, TIG and gas. I have two gas tanks in my garage, so I'll be using those. Good old acetylene and oxygen, so I'm limited to steel.

I've searched and seen a ton of options for making brackets that would assemble with hand tools. I'm interested in welding up some stuff that I bolt to the bike using existing mounts, and perhaps drilling holes in the passenger grab handle if necessary.

So, does anyone know of any pre-curved tubular bar stock that would be a good candidate for this project? I've had the thought of going down to Wallmart and buying a cheap deck table or some cheap coffee table that uses tubular bars, and hacksawing as needed. Suggestions?

Also, what type of hard case should I use? I'm not above bolting a plastic tackle or tool box. Don't care TOO much how it looks, just as long as it's functional. I thought of using Jerrycans and just cutting them 3/4 the way up and adding hinges, but it's hard to find Jerrycans in good condition. I'd prefer that they be silver or flat black, not olive drab. Thoughts on types of cases?

Thanks in advance.

Can't help you too much with the rack, but I know a lot of people use Pelican cases or something similar. Not the prettiest thing, but it sounds like you don't care too much. They have a lot more function than something from givi and are much cheaper and durable. They come in all sorts of sizes so you can decide how much you need to carry.
Also check out Vanguard USA for some similar cases cheaper.

pronator made her own rack and has a really good write up of how she made it and what material she used. Look up her post, I'm sure that will point you in the right direction...

What exactly is a jerrycan? Is it the metal ammo cans you get at army surplus stores and gun shows? I've got a few of those in real good shape along with a stock grab handle is you want a spare in case you mess up the first one if you wanna buy them.

Get yourself one of those Chinese knockoff Hossfeld benders and go to town. 

Alternatively, somebody came up with a DIY rack using 3/4 EMT components.  Don't remember who though.

I'm working on mounts for Pelican 1510's on the SV right now, so I'm biased when it comes to cases.  Givi cases just seem so flimsy. 

Quote from: SecondsFromTheFall on October 13, 2008, 01:49:58 PM
What exactly is a jerrycan? Is it the metal ammo cans you get at army surplus stores and gun shows? I've got a few of those in real good shape along with a stock grab handle is you want a spare in case you mess up the first one if you wanna buy them.

Jerry cans are those big red gas cans you see on 4x4s all the time with the X stamped into the side. They are so named because the Germans used them during WWII and they were so superior to the British equivalent, the British first just captured as many as possible and later reverse engineered the design. They were so much better because of the stamped sides, which made them stronger than the British version that had straight sides and were nicknamed "flimsies."

Quote from: GeeP on October 13, 2008, 01:52:03 PM
Alternatively, somebody came up with a DIY rack using 3/4 EMT components.  Don't remember who though.

If you weld EMT, which is galvanized, read this first:
http://www.sperkoengineering.com/html/articles/WeldingGalvanized.pdf

It can be done safely, but it's not as simple as welding uncoated steel.

I have a Suzuki OEM cargo rack, onto which is mounted a GIVI Flow top case.  Mine holds a full-face helmet and only a little else.  Over time, the weight of the cargo rack and GIVI case began to crack the mounting area (where the grab bar formerly attached).  My solution was to reinforce that mounting point with 1/8" mild steel bar (I predrilled holes to allow the mounting bolts to remain in use) which I welded in place.  I repainted the patched area and it has held just fine.

My bike (and some bald guy)  :

I also mounted a Givi case to the standard Suzuki rack on my 02 GS and the frame cross member began to crack the same way as trumpetguys so I added a couple struts down to the top of the rear fender to brace it.  Been there now as solid as a rock for over 4 years and 55k miles.

http://img.photobucket.com/albums/v443/jcp8832/GiviRackPics.jpg

Made a rack out of aluminum angle bolted together with stainless screws and nuts that mounted to the grab handle and used it for soft luggage on my 97 GS for tens of thousands of miles.

http://img.photobucket.com/albums/v443/jcp8832/gsrackpics.jpg

I neglected to mention that I added struts that go down into the tubes on the top of the frame (behind back end of the the side panels).  I cut a hole in the end of each side panel to allow the strut to pass through.  I also put clevis pins through the frame tube and strut tube because they kept popping out over bumps.