robust rack construction in the UK??

**andybee** · #1 25 Apr 2002

i all,

I've just bought a new Honda XR650L for a trip to the Tenere early next year. I also have 2 Bernd Tesch aluminium panniers, each with 1 13 litre slide-in fuel/water tank.

My problem now is joining the bike to the panniers!! I'm not aware of a company who make a strong rack for this model (certainly Tesch and Touratech don't). Becasue of the tanks, each pannier will weigh up to 25kg when full.

I therefore wonder if anyone knows a person in the UK who can fabricate a rack (and strengthen my rear sub frame), to order, so to speak. I've got a pretty clear idea of what I need, but would appreciate going through it with someone a bit more 'technical'.

Thanks,

AndyBee

**harvey** · #2 25 Apr 2002

I know just the man - Ernie lives on the Isle of Sheppey in North Kent and made an excellent job of fabricating frames and strengthening the sub-frames for our two BMWs. He's an overlander (R1100GS) and a metalsmith so he knows what he's doing and can tailor the frames to suit your needs, ie add racks, brackets, etc.
If you want to see the work he did for us, have a look at the 'bikes' page on our site www.chasingthesun.org.
With 10,000 miles and a few tumbles under our belts I can vouch for the standard of Ernie's work - top class.
You can contact him by email at
EMECHUGGGSSKI@aol.com.
Harvey

------------------
no pipe, no slippers
www.chasingthesun.org

**Spud** · #3 25 Apr 2002

I too can vouch for Ernie's work.

He recently fabricated some crash bars front and rear for my Dommie (rear also serve as pannier racks). I can safetly say that the quality of the welding is superb (all powder coated too). Price superb considering it's all handmade.

I haven't placed any pics on my website yet as I haven't finished it, but can send you some if you like.

Ernie's site:
http://www.overland-solutions.com

[This message has been edited by Spud (edited 25 April 2002).]

**wbagwell** · #4 26 Apr 2002

Hi Andy,
Both Happy Trails and Moto Sport Panniers make racks for the XR650L. I have the Happy Trails rack for my bike and I'm very happy with it - though I've never put it to the test on anything like a trip to the Tenere.

http://www.happy-trail.com
http://www.motosportpanniers.com

Pictures of the rack/panniers at:
http://www.geocities.com/wwbagwell/

Cheers,
Wright Bagwell

**davidlomax** · #5 6 May 2002

What about those of use who live further north!!?

Anyone know of any interested parties in the Manchester/ North West regions?

Many Thanks

**Tony Robson** · #6 7 May 2002

For your help:

Quote:

Originally posted by davidlomax:
What about those of use who live further north!!?

Anyone know of any interested parties in the Manchester/ North West regions?

Many Thanks

I have just had a rack built for my XTZ660 by a company called Brunstock engineering in Carlisle. I rand around a few places in the area and opted for one who sounded like a nice bloke and keen to have a go.

He had never done anything like it before - and was open about the fact - but he had a go based purely on pictures from the touratech catalogue.

Once built he happilly adjusted them to my own personal requirement as I have one box 4cm wider than the other.

Whole rack - £80.

I know he is about aas far north as you can get without going to scotland but he si good.. alternatively get the phone book out and phone around. The smaller the batter I think and speak to them in detail. I think 1st impressions count so go on your gut instinct when you speak to these people.

A friend is getting 2 racks made up by him very soon for a dommie and tenere so he has alot more experience..

Hope this helps.

Tony.

[This message has been edited by Tony Robson (edited 07 May 2002).]

**davidlomax** · #7 11 May 2002

Thanks Tony,

Carlisle is a little far north, but £80 seems a fantastic price!! Possibly worth the drive if my own attempts fail.

I am hoping to weld up my own system using some mild steel tube and a Mig welder aquired from a mate. I figure for the price of steel tube (very little) I can have a go and see what happens. I realise the welding has to fully penetrate the tube and destructive testing will be a part of the the process. If all goes well I'll let you all know how difficult it really is. Otherwise it'll be Carlisle or Loads of phone calls locally!!

Cheers!

**andybee** · #8 13 May 2002

thanks for your replies guys. i've gone from being totally stuck to spoiled for choice!! can't wait for the massive improvement to handling and agility these panniers will bring about :-)

cheers,

Andy