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The Rack


I need a solution to the weak rear rack so I can mount my Givi topbox with confidence.  Having somewhere to store one, or even two helmets while wandering around is just so handy.  Not to mention doing the shopping.

Himalayan broken rackThe rack is not really designed for much load and it tends to break.

Himalyan broken rack They tend to break at the same point where this a high cantilever load on a piece of bent pipe.

Rac k support This solution shows extra supports clipped to the rear of the rack and to the frame. as shown here.
The extra supports will need to be slightly bend and may interfere with subsequent fitting of pannier racks

Welded Himalayan rackThis solution involves welding.
It moves the stress point away from the weak area to the other side of the rear supports.

I think the breaks have occurred due to metal fatigue as the rack flexes slightly up and down, If you thump the rack you can feel it vibrating at a high frequency. The tubing used on the rack is 16mm, but measure a bit thicker probably due to the paint.

I think all I need are tubes following the line of where the bottom weld is in the picture above. This will transfer some of the load to the other side of the rear support and should stop the rack flexing at the usual break point.
I have no welding equipment so it will have to be nuts and bolts.
Wire rope clamps at 16mm are available which should clamp solidly onto the rack. I have ordered 4, as well as 600mm of 16mm steel tubing. 


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