OK dredging my memory, this is how I did it
Tail Rack:
Materials:
25 X 2 mm steel strip
15 X 2mm angle
and 4 X 6mm bolts which I sawed the heads off
I cant remember the length off hand but checked there
would only be thread showing inside when fitted.
About 50mm or so I think.
First I cut two 150mm lengths of strip and drilled
8mm holes at the relevant points
this allowed for the angle of the bolts.
I put a large piece of cardboard box over the tailpeice
and peirced the holes to hold the bolts in position.
(The old box helps protect the bike from sparks as well)
I put the strip in place and pushed the bolts down through
whilst checking I had enough thread inside for thick rubber
tap washers and then some.
Next a few quick tacks on each bolt to hold them in place
and filled in with the peices away from the bike.
lastly I ground off any protuding bolts flush (ish).
when they were cool I fitted the peices to the tail section
I made the plate for the box and offered it up to the rack
to get an idea of what legs I would need.
these were cut from the 25mm strip.
You have to bear in mind the size of the box and its position
whilst doing this and I finally decided on the sizes and positions
of the legs.
I cut them to length amd tacke them on the late and offerd it up again
and few wee cuts and mods here and there and a quick tack on to
the bases
I then rmeoved it for final welding, clean up and painting
There are some strips of old inner tube under the base and thick
tap washers between the nut and washers and GRP tail section inside
The first plate was quite big in order to accept an old Rickman box
which was permanently bolted on.
and has since been hacked down for a Givi plate/box I was given
It was only a Monolock but hey its free.
I only have two bolts on this plate and will mod it to accept
a more robust fixing later.
Its been on there for over a year now and had all manner of stuff on it
without problems.
Flip up
Why?
I rode back to Bristol from near Aberdeen in Scotland one day and the RT fairing was great but the wind noise around my head was really awful
After a couple of hours I was trying to crouch down behind the screen
for some relief from the noise.
I'm 6 foot three BTW, were I not so tall this may not be an issue.
the RT screen has a flip up, but in my case it doesnt help.
Shortly after, I found a peice of perspex lying in the back garden of my sons house and thought "Aha! I'll get experimenting"
I broke scratched and split a lot of it, luckily it was a large sheet
and after a couple of tries made up the current one.
I made the outline first then use a hot air gun to get it to follow the shape of the original flip up.
Thick welding gloves really helped save my fingers here.
I used rubber washers and O rings on the fixing bolts to try and prevent
stress fractures
I know a better quality perspex would be better but this
is an experiment, a work in progress if you like.
Anyway with it fitted I took the bike for a spin up the motorway
and was delighted that I'd proved the concept.
I found I could ride at 100MPH with my visor open ( theoretically Officer) and on longer rides since, its been a success.
Now I have the pattern, I can use it to make another from better quality
clearer material when I get hold of some.
the shiny strip was just a bit of left over tank edging I bodged on.